Electric vehicle battery current collector

ABSTRACT

Systems and methods for a battery pack to power an electric vehicle are provided. The battery pack can include a plurality of battery modules having a plurality of battery blocks. The battery blocks can include a plurality of cylindrical battery cells. A first current collector can include a conductive layer to couple the first current collector with positive terminals of the plurality of cylindrical battery cells. A second current collector can include a conductive layer to couple the second current collector with negative terminals of the plurality of cylindrical battery cells. The first current collector, second current collector, and an isolation layer can include a plurality of apertures to expose the positive terminals of the plurality of cylindrical battery cells. The positive terminals can extend through the plurality of apertures to couple with the conductive layer of the first current collector.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Application 62/557,680, titled “CURRENTCOLLECTOR DESIGN”, filed on Sep. 12, 2017. The entire disclosure ofwhich is incorporated herein by reference in its entirety.

BACKGROUND

Vehicles such as automobiles can include power sources. The powersources can power motors or other systems of the vehicles.

SUMMARY

In at least one aspect, a system to power electric vehicles is provided.The system can include a battery pack to power an electric vehicle. Thebattery pack can reside in the electric vehicle and include a pluralityof battery modules. Each of the plurality of battery modules can includea plurality of battery blocks. A first battery block of the plurality ofbattery blocks can include a pair of battery block terminals. The firstbattery block can include a plurality of cylindrical battery cells. Eachof the plurality of cylindrical battery cells can include a positiveterminal and a negative terminal. A first current collector can includea conductive layer. The conductive layer of the first current collectorcan couple the first current collector with positive terminals of theplurality of cylindrical battery cells at first ends of the plurality ofcylindrical battery cells. A second current collector can include aconductive layer. The conductive layer of the second current collectorcan be electrically isolated from the conductive layer of the firstcurrent collector by an isolation layer. The conductive layer of thesecond current collector can couple the second current collector withnegative terminals of the plurality of cylindrical battery cells at thefirst ends of the plurality of cylindrical battery cells. The firstcurrent collector can include a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells tocouple with the conductive layer of the first current collector. Theisolation layer can include a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells. Thepositive terminals of the plurality of cylindrical battery cells canextend through the plurality of apertures of the isolation layer tocouple with the conductive layer of the first current collector. Thesecond current collector can have a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells and toexpose portions of the negative terminals of the plurality ofcylindrical battery cells to connect to the conductive layer of thesecond current collector. The positive terminals of the plurality ofcylindrical battery cells can extend through the plurality of aperturesof the second current collector to couple with the conductive layer ofthe first current collector.

In another aspect, a method of providing a system to power an electricvehicle is provided. The method can include providing a battery pack topower an electric vehicle. The battery pack can reside in the electricvehicle and can include a plurality of battery modules. Each of theplurality of battery modules can include a plurality of battery blocks.A first battery block of the plurality of battery blocks can include apair of battery block terminals. The method can include disposing aplurality of cylindrical battery cells in the first battery block. Eachof the cylindrical battery cells can include a positive terminal and anegative terminal. The method can include aligning a plurality ofapertures of a first current collector having a conductive layer. Theplurality of apertures of the first current collector can be aligned toexpose positive terminals of the plurality of cylindrical battery cellsto couple with the conductive layer of the first current collector. Themethod can include aligning a plurality of apertures of an isolationlayer. The plurality of apertures of the isolation layer can be alignedto expose the positive terminals. The positive terminals of theplurality of cylindrical battery cells can extend through the pluralityof apertures of the isolation layer to couple with the conductive layerof the first current collector. The method can include aligning aplurality of apertures of a second current collector having a conductivelayer. The plurality of apertures of the second current collector can bealigned to expose the positive terminals of the plurality of cylindricalbattery cells to couple with the conductive layer of the first currentcollector. The plurality of apertures of the second current collectorcan be aligned to expose portions of the negative terminals of theplurality of cylindrical battery cells to connect to the conductivelayer of the second current collector. The method can include connectingthe first current collector to the positive terminals of the pluralityof cylindrical battery cells at first ends of the plurality ofcylindrical battery cells. The method can include connecting the secondcurrent collector to negative terminals of the plurality of cylindricalbattery cells at the first ends of the plurality of cylindrical batterycells.

In another aspect, a method is provided. The method can includeproviding a system to power electric vehicles. The system can include abattery pack to power an electric vehicle. The battery pack can residein the electric vehicle and include a plurality of battery modules. Eachof the plurality of battery modules can include a plurality of batteryblocks. A first battery block of the plurality of battery blocks caninclude a pair of battery block terminals. The first battery block caninclude a plurality of cylindrical battery cells. Each of the pluralityof cylindrical battery cells can include a positive terminal and anegative terminal. A first current collector can include a conductivelayer. The conductive layer of the first current collector can couplethe first current collector with positive terminals of the plurality ofcylindrical battery cells at first ends of the plurality of cylindricalbattery cells. A second current collector can include a conductivelayer. The conductive layer of the second current collector can beelectrically isolated from the conductive layer of the first currentcollector by an isolation layer. The conductive layer of the secondcurrent collector can couple the second current collector with negativeterminals of the plurality of cylindrical battery cells at the firstends of the plurality of cylindrical battery cells. The first currentcollector can include a plurality of apertures to expose the positiveterminals of the plurality of cylindrical battery cells to couple withthe conductive layer of the first current collector. The isolation layercan include a plurality of apertures to expose the positive terminals ofthe plurality of cylindrical battery cells. The positive terminals ofthe plurality of cylindrical battery cells can extend through theplurality of apertures of the isolation layer to couple with theconductive layer of the first current collector. The second currentcollector can have a plurality of apertures to expose the positiveterminals of the plurality of cylindrical battery cells and to exposeportions of the negative terminals of the plurality of cylindricalbattery cells to connect to the conductive layer of the second currentcollector. The positive terminals of the plurality of cylindricalbattery cells can extend through the plurality of apertures of thesecond current collector to couple with the conductive layer of thefirst current collector.

In another aspect, an electric vehicle is provided. The electric vehiclecan include a battery pack to power an electric vehicle. The batterypack can reside in the electric vehicle and include a plurality ofbattery modules. Each of the plurality of battery modules can include aplurality of battery blocks. A first battery block of the plurality ofbattery blocks can include a pair of battery block terminals. The firstbattery block can include a plurality of cylindrical battery cells. Eachof the plurality of cylindrical battery cells can include a positiveterminal and a negative terminal. A first current collector can includea conductive layer. The conductive layer of the first current collectorcan couple the first current collector with positive terminals of theplurality of cylindrical battery cells at first ends of the plurality ofcylindrical battery cells. A second current collector can include aconductive layer. The conductive layer of the second current collectorcan be electrically isolated from the conductive layer of the firstcurrent collector by an isolation layer. The conductive layer of thesecond current collector can couple the second current collector withnegative terminals of the plurality of cylindrical battery cells at thefirst ends of the plurality of cylindrical battery cells. The firstcurrent collector can include a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells tocouple with the conductive layer of the first current collector. Theisolation layer can include a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells. Thepositive terminals of the plurality of cylindrical battery cells canextend through the plurality of apertures of the isolation layer tocouple with the conductive layer of the first current collector. Thesecond current collector can have a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells and toexpose portions of the negative terminals of the plurality ofcylindrical battery cells to connect to the conductive layer of thesecond current collector. The positive terminals of the plurality ofcylindrical battery cells can extend through the plurality of aperturesof the second current collector to couple with the conductive layer ofthe first current collector.

These and other aspects and implementations are discussed in detailbelow. The foregoing information and the following detailed descriptioninclude illustrative examples of various aspects and implementations,and provide an overview or framework for understanding the nature andcharacter of the claimed aspects and implementations. The drawingsprovide illustration and a further understanding of the various aspectsand implementations, and are incorporated in and constitute a part ofthis specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not necessarily intended to be drawn toscale. Like reference numbers and designations in the various drawingsindicate like elements. For purposes of clarity, not every component maybe labelled in every drawing. In the drawings:

FIG. 1 depicts an exploded view of an illustrative embodiment of asystem to power an electric vehicle;

FIG. 2 depicts an exploded view of an illustrative embodiment of asystem to power an electric vehicle;

FIG. 3 depicts an isometric view of an illustrative embodiment of asystem to power an electric vehicle;

FIG. 4 depicts a top view of an illustrative embodiment of a system topower an electric vehicle;

FIG. 5 depicts an isometric view of an illustrative embodiment of asystem to power an electric vehicle;

FIG. 6 depicts a top view of an illustrative embodiment of a system topower an electric vehicle;

FIG. 7 is a block diagram depicting a cross-sectional view of an exampleelectric vehicle installed with a battery pack;

FIG. 8 is a flow diagram depicting an illustrative embodiment of amethod for providing a system to power an electric vehicle;

FIG. 9 is a flow diagram depicting an example method for providing asystem to power an electric vehicle;

FIG. 10 depicts a top view of the battery module illustrating coatedsurfaces and exposed surfaces the battery blocks; and

FIG. 11 depicts a view of a spatial relationship between a positivecurrent collector, an isolation layer, and a negative current collectorrelative to a battery cell.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various conceptsrelated to, and implementations of, methods, apparatuses, devices, andsystems for providing a system to power electric vehicles having one ormore current collectors is provided. The various concepts introducedabove and discussed in greater detail below may be implemented in any ofnumerous ways.

With reference to the FIGS., the systems, methods, devices, andapparatuses of the present disclosure relate generally to batteryrelated energy storage devices, including but not limited to batteryblocks and battery packs to power electric vehicles. There is anincreasing demand for higher capacity battery cells for higher power,higher voltage battery packs, to support applications in plug-in hybridelectrical vehicles (PHEVs), hybrid electrical vehicles (HEVs),electrical vehicle (EV) systems, or stationary energy storage, forexample. Challenges with increasing the capacity at the battery celllevel include packaging efficiency.

The present disclosure is directed to systems and methods for providingsystems to power electric vehicles. The systems can include a batterypack to power an electric vehicle. The battery packs having a layeredcurrent collector formed from conductive and nonconductive structures toprovide current collectors for battery cells. For example, the batterypack can include one or more battery modules, and each of the batterymodules can include one or more battery blocks. Each of the batteryblocks can include a plurality of battery cells. Each of the pluralityof battery cells can have a voltage of up to 5 volts (or other limit)across terminals of the corresponding battery cell. The battery blockcan include an arrangement of the plurality of battery cellselectrically connected in parallel. Each cell of the plurality ofbattery cells can be spatially separated from each of at least oneadjacent cell by, for example, two millimeter (mm) or less. The batterycells can be homogeneous or heterogeneous in one or more aspects, suchas height, shape, voltage, energy capacity, location of terminal(s) andso on. The battery cells of a battery block can be coupled with thelayered current collector (e.g., stacked current collector) to powerelectric an vehicle. The current collector configuration as describedherein can support positive and negative connections at a top portion ofthe battery cells such that positive and negative terminals couple withthe same end of the battery cells for ease of assembly.

FIG. 1, among others, depicts a partially exploded view of an example ofa battery block 100. The battery block 100 can include a plurality ofbattery cells 105 disposed between a first cell holder 125 and a secondcell holder 130. The first cell holder 125 and the second cell holder130 can house, support, hold, position, or arrange the battery cells 105to form the battery block 100 and may be referred to herein asstructural layers. For example, the first cell holder 125 and the secondcell holder 130 can hold the battery cells 105 in predeterminedpositions or in a predetermined arrangement to provide appropriatespacing or separation between each of the battery cells 105.

The first cell holder 125 can include a plurality of layers (e.g.,conductive layers, non-conductive layers) that couple the plurality ofbattery cells 105 with each other. The first cell holder 125 can includealternating or interleaving layers of conductive layers andnon-conductive layers. For example, the first cell holder 125 mayinclude a positive conductive layer 110, an isolation layer 115 having anon-conductive material, and a negative conductive layer 120. The firstcell holder 125 can include, be coupled with or house the plurality oflayers to provide current collectors for the plurality of battery cells105. For example, and as depicted in FIG. 1, the first cell holder 125can include, be coupled with or house a first current collector 110(e.g., positive current collector), an isolation layer 115 (e.g.,non-conductive layer), and a second current collector 120 (e.g.,negative current collector). FIG. 1 depicts a second surface (e.g.,bottom surface) of the first current collector 110 disposed over,coupled with, or in contact with a first surface (e.g., top surface) ofthe isolation layer 115. A second surface (e.g., bottom surface) of theisolation layer 115 is disposed over, coupled with, or in contact with afirst surface (e.g., top surface) of the second current collector 120. Asecond surface (e.g., bottom surface) of the second current collector120 is disposed over, coupled with, or in contact with a first surface(e.g., top surface) of the first cell holder 125.

The battery cells 105 of a battery block can couple with themulti-layered current collector (e.g., stacked current collector) thehaving a first current collector 110 (e.g., positive current collector)and the second current collector 120 (e.g., negative current collector)separated by an isolation layer 115 (e.g., insulation material,nonconductive material). For example, the battery cells 105 can have anegative portion (e.g., negative can, negative housing) and a positiveportion (e.g., positive tab on cell lid) and the coupling strategy forcoupling the negative and positive portions to current collectors can bedifficult. A multi-layered current collector, as described herein, caninclude multiple layers to couple with the negative portion and thepositive portion of each of the battery cells 105 and from a common end(e.g., top end, bottom end) of the battery cells 105. For example, a topend (or first end) of each of the battery cells 105 may include a rim orlid having a positive portion. A negative portion and tabs from a firstcurrent collector 110 and a second current collector 120 of themulti-layered current collector can couple with the positive portion andthe negative portion of the rim or lid, respectively.

The multi-layered current collector can include the positive (or first)current collector 110 comprising a first conductive layer, and anegative (or second) current collector 120 comprising a secondconductive layer, that can be laminated together using an isolationlayer 115 that is disposed between the positive current collector 110and the negative current collector 120. The isolation layer 115 can holdor bind the positive current collector 110 and negative currentcollector 120 together. The isolation layer 115 can include or useadhesive(s) or other binding material(s) or mechanism(s) to hold or bindthe positive current collector 110 and negative current collector 120together. The isolation layer 115, the positive current collector 110and the negative current collector can be held or bound together to forma multi-layer composite, sometimes collectively referred as amulti-layered current collector. A lamination material or laminationcoating can be disposed over each of the layers as a conformal coatingto protect against a short circuit condition from the positive andnegative current collectors 110, 120. Apertures can be formed in each ofthe layers to expose the weld areas of terminals of the battery cells105 when the multi-layered current collector is coupled with or disposedover the plurality of battery cells 105. Negative tabs can couple thenegative current collectors 120 to the battery cells 105, usingtechniques, such as but not limited to, laser welding or wire bonding.Positive tabs can couple the positive current collectors 110 to thebattery cells 105 in some implementations, using techniques, such as butnot limited to, laser welding or wire bonding.

In an example multi-layered current collector, a bottom layer caninclude the negative current collector 120. The negative currentcollector 120 can include a conductive material, such as but not limitedto a metal (e.g., copper, aluminum), or a metallic material. Thenegative current collector 120 can have a thickness in a range from 1 mmto 8 mm, (e.g., a value less than 5 mm). The negative current collector120 can be coupled with or disposed on a cell holder. The negativecurrent collector 120 can include a plurality of apertures 150 toreceive or engage a rim portion (or cap portion, or other portion) ofeach of the plurality of battery cells 105 such that a negative tabportion of each of the plurality of apertures 150 couples with orcontacts at least two battery cells 105. The negative tab can be part ofor welded or wire bonded to the negative current collector 120. Thenegative tab can be welded or wire bonded to the negative terminals ofthe battery cells 105. The multi-layered current collector can includeresistive welding in which a bondhead can couple with or contact thenegative current collector 120 directly and weld to the rim of thebattery cell 105 to form the negative connection.

In an example multi-layered current collector, a middle layer caninclude the isolation layer 115 and a top layer may include the positivecurrent collector 110. The positive current collector 110 can include aconductive material, such as but not limited to copper or aluminum andcan have a thickness in a range from 1 mm to 8 mm (e.g., less than 5mm). The positive current collector 110 can include a plurality ofapertures 140 to receive or engage a positive tab that extends thoughapertures of one or more layers of the multi-layered current collectorand couples with a positive terminal (e.g., positive cap area) of abattery cell 105. The positive tab can be welded or wire bonded to thepositive current collector 110 and the positive terminal of the batterycell 105.

Cell holders 125, 130 can hold or maintain battery cells 105 in aspatial arrangement with respect to one another. The cell holders 125,130 can provide spatial separation between adjacent battery cells 105 ofless than 1 mm (or less than 1.2 mm, or less than 2 mm, or otherpredetermined values or ranges). Adjacent battery cells 105 can refer toclosest neighbor battery cell 105 pairs. Spatial separation may beuniform across adjacent battery cell 105 pairs or may vary acrosscertain groups of battery cell 105 pairs. The arrangement of batterycells 105 within the battery block 100, including the spatial separationbetween adjacent battery cells 105, can provide a volumetric energydensity that is higher than that of single battery cell implementations.The spatial separation between adjacent battery cells 105 can allow forsuitable or sufficient thermal dissipation between battery cells 105,avoidance of electrical arcing between battery cells 105, and possiblyother protective features. The cell holders 125, 130 can incorporatestructures, such as channels or routing vents, to receive, direct orrelease high energy or high pressure gaseous release. The channels orrouting vents can receive gaseous release through vents incorporated inthe battery cells 105, for instance by coupling to these vents. The cellholders 125, 130 can include material that is suitably thermallyconductive, to transfer, propagate and dissipate heat resulting from thebattery cells 105.

The material and structural configuration of the cell holders 125, 130can provide spatial separation between cells such that creepage orclearance (creepage-clearance) requirements are met or exceeded forsupporting a certain voltage (e.g., 400V or 450V, among other voltages)across terminals of a battery pack such as battery pack 740 as in FIG. 7or of a battery module 500 (e.g., 60 V) that is implemented using thebattery blocks 100. Creepage can refer to a separation (e.g., shortestdistance) between connection or weld points (e.g., betweenlike-terminals) of battery cells 105 as measured along a surface of abus-bar, circuit board or other connecting structure. Clearance canrefer to a separation (e.g., shortest distance) between connection orweld points between (e.g., like-terminals of) battery cells 105 asmeasured through air or space.

The busbar and the current collector can be referred to interchangeablyherein. A busbar can include, geometrically or functionally, a strip orbar that carries current. A current collector can have a structure thatis not geometrically a strip or bar, that carries current. A busbar or acurrent collector can include a conductive piece of metal that iselectrically connected to battery cells (e.g., terminals of the batterycells) and that carries current.

A battery cell 105 can be cylindrical in shape or structure. The batterycell 105 can have one cap or two caps, including a top cap. The top capcan include, incorporate or hold a tab or conductive structure locatedwithin or at a center of the top cap, which forms a positive electricalterminal of the battery cell 105. The battery cell 105 can have ametallic or conductive can or housing. The housing may operate as themain casing for the battery cell. The can or housing can include asurface structure that forms a negative electrical terminal of thebattery cell. The housing can extend over the cylindrical or curvedsurface of the battery cell, and can extend over one end of the batterycell. FIG. 1 shows multiple ones of an example embodiment of acylindrical battery cell 105.

Battery cells 105 can include cylindrical, prismatic can, or polymerpouch formats. Cylindrical cells can be used in low voltageapplications, small format devices (e.g., power tools). The batteryblock described herein can include cylindrical battery cells 105packaged into a prismatic format for increased utility in larger batterymodules. For example, each of the cylindrical battery cells 105 can havethe same shape and dimensions. The cylindrical battery cells 105 can bearranged within a battery block in a predetermined order such that theindividual cylindrical battery cells 105 can be individually replaced oradditional cylindrical battery cells can be added to increase thecapacity of the respective battery block. The battery blocks 100 canhave the same shape and dimensions and can be combined with one or moredifferent battery blocks to form a battery module or a battery pack.

The battery block design described herein can increase yield rate andimprove system reliability. If one battery cell 105 were to fail in abattery block 100, it does not compromise the entire block 100. Certainbattery cells 105 can be replaced in a battery block 100 to make up forany lost capacity. For example, a monolithic battery cell 105 may berendered inoperable if any portion of the battery cell 105 is to fail.For example, if a 50 Ampere-hour (Ah) battery block 100 containing ten(10) 5 Ah battery cells 105 has an individual battery cell 105 that hasfailed, the battery block 100 then becomes 45 Ah, and the battery packsystem would only see a loss of 5 Ah. The cylindrical battery cells 105can provide a battery block capacity to store energy that is at leastfive times greater than a battery cell capacity of each of the pluralityof cylindrical battery cells, and the battery blocks 100 can have avoltage of up to 5 volts across the pair of battery block terminals ofthe respective battery blocks 100.

The first cell holder 125 can hold, house or align the first currentcollector 110, the isolation layer 115, and the second current collector120. For example, the first cell holder 125 can include a border orraised edge formed around a border of the first cell holder 125 suchthat the first current collector 110, the isolation layer 115, and thesecond current collector 120 can be disposed within the border or raisededge. The plurality of battery cells 105 can be disposed or positionedbetween a second surface (e.g., bottom surface) of the first cell holder125 and a first surface (e.g., top surface) of the second cell holder130. The first cell holder 125 and the second cell holder 130 can hold,house or align the plurality of battery cells 105 using a plurality ofapertures.

For example, the first current collector 110, the isolation layer 115,the second current collector 120, the first cell holder 125, and thesecond cell holder 130 can include a plurality of apertures. The firstcurrent collector 110 can include a first plurality of apertures 140having a first shape. The isolation layer 115 can include a secondplurality of apertures 145 having a second shape. The second currentcollector 120 can include a third plurality of apertures 150 having athird shape. The first cell holder 125 can include a fourth plurality ofapertures 155 having a fourth shape. The second cell holder 130 caninclude a fifth plurality of apertures 160 having a fifth shape. Theapertures 140, 145, 150, 155, 160 can include an opening or hole formedthrough each of the respective layers, or a recess formed into therespective layers.

The shape, dimensions, or geometry of one or more of the first pluralityof apertures 140, the second plurality of apertures 145, the thirdplurality of apertures 150, the fourth plurality of apertures 155, andthe fifth plurality of apertures 160 can be different. For example, thefirst plurality of apertures 140 can be formed having a circular shapeand the second plurality of apertures 145 can be formed having arectangular shape. The shape, dimensions, or geometry of one or more ofthe first plurality of apertures 140, the second plurality of apertures145, the third plurality of apertures 150, the fourth plurality ofapertures 155, and the fifth plurality of apertures 160 can be the sameor similar. For example, each of the plurality of apertures 140, 145,150, 155, 160 can be formed having a circular shape. The shape,dimensions, or geometry of the apertures 140, 145, 150, 155, 160 can beselected according to an arrangement or separation of the battery cells105. The shape, dimensions, or geometry of the apertures 140, 145, 150,155, 160 can be selected based at least in part on the shape,dimensions, or geometry of the battery cells 105. For example, theplurality of battery cells 105 can be disposed or positioned between asecond surface (e.g., bottom surface) of the first cell holder 125 and afirst surface (e.g., top surface) of the second cell holder 130. Thefirst cell holder 125 can hold, house or align the plurality of batterycells 105 using the fourth plurality of apertures 155 and the secondcell holder 130 can hold, house or align the plurality of battery cells105 using the fifth plurality of apertures 160. The battery cells 105can include a rim portion 135 that is formed at, disposed at, or coupledwith a first end or top end of each of the battery cells 105. The rimportion 135 of each battery cell 105 can be disposed in, coupled with,or in contact with at least (an edge, boundary, side, surface orstructure of) one aperture of the fourth plurality of apertures 155 ofthe first cell holder 125. Each of the battery cells 105 can be disposedwithin the battery block 100 such that a second end or bottom end of abattery cell 105 is disposed in, coupled with or in contact with atleast (an edge, boundary, side, surface or structure of) one aperture ofthe fifth plurality of apertures 160 formed in the second cell holder130.

The apertures 140, 145, 150 of the first current collector 110, theisolation layer 115, and the second current collector 120 can allow aconnection to a positive current collector (e.g., first currentcollector 110) or negative current collector (e.g., second currentcollector 120) from each of the battery cells 105. For example, awirebond can extend through the apertures 140, 145, 150 to couple apositive terminal or surface of a battery cell 105 with the firstcurrent collector 110. Thus, the apertures 140, 145, 150 can be sized tohave a diameter or opening that is greater than a diameter orcross-sectional shape of the wirebond. A negative tab can extend fromthe second current collector 120 and be connected to negative surfacesor terminals on at least two battery cells 105. For example, a wirebondcan extend from the negative tab to couple with a portion of a negativeterminal on a battery cell 105 that is exposed by the aperture 150.Thus, one or more of the apertures 140, 145, 150 can be sized to havedimensions that are greater than the dimensions of the negative tab, orgreater than a diameter or cross-sectional shape of the wirebond. Theshape of the apertures 140, 145, 150, 155, 160 can include a round,rectangular, square, or octagon shape as some examples. The dimensionsof the apertures 140, 145, 150, 155, 160 can include a width of 21 mmfor instance.

The apertures 140, 145, 150 can be formed such that they are smallerthan the apertures 155, 160. For example, the apertures 155 and 160 canhave a diameter in a range from 10 mm to 35 mm (e.g., 18 mm to 22 mm).The apertures 140, 145, 150 can have a diameter in a range from 3 mm to33 mm. If the apertures 155, 160 are formed having a square orrectangular shape, the apertures 155, 160 can have a length in a rangefrom 4 mm to 25 mm (e.g., 10 mm). If the apertures 155, 160 are formedhaving a square or rectangular shape, the apertures 155, 160 can have awidth in a range from 4 mm to 25 mm (e.g., 10 mm). For example, theapertures 155, 160 can have dimensions of 10 mm×10 mm. If the apertures140, 145, 150 are formed having a square or rectangular shape, theapertures 140, 145, 150 can have a length in a range from 2 mm to 20 mm(e.g., 7 mm). If the apertures 140, 145, 150 are formed having a squareor rectangular shape, the apertures 140, 145, 150 can have a width in arange from 2 mm to 20 mm (e.g., 7 mm). For example, the apertures 140,145, 150 can have dimensions of 7 mm×7 mm.

Apertures 145 can be formed such that they are smaller (e.g., havesmaller dimensions) or offset with respect to apertures 140. Forexample, apertures 145 can correspond to apertures 140, such as havingthe same geometric shape with just an offset to make the apertures 145smaller with respect to apertures 140. For example, the offset can be ina range from 0.1 mm to 6 mm depending on isolation, creepage, andclearance requirements. Apertures 145 can be sized the same as oridentical to aperture 140.

The apertures 140, 145, 150 can be formed in a variety of shapes. Forexample, the apertures 140, 145, 150 may not be formed as distinctpatterned openings or formed having distinct patterned openings. Forexample, the apertures 140, 145, 150 can be formed as a geometric cutfrom the sides of the respective one of layers 110, 115, 120. Theapertures 140, 145, 150 can be formed as half circular cutouts aroundthe perimeter of each of the respective one of layers 110, 115, 120,respectively.

The first current collector 110 and the second current collector 120 caninclude conductive material, a metal (e.g., copper, aluminum), or ametallic material. The first current collector 110 can be a positivecurrent collector layer or positively charged current collector. Thesecond current collector 120 can be a negative current collector layeror negatively charged current collector. The first current collector 110and the second current collector 120 can have a thickness in a range of1 mm to 8 mm (e.g., 1.5 mm) for example. The first current collector 110and the second current collector 120 can have the same length as batteryblock 100. The first current collector 110 and the second currentcollector 120 can have the same width as battery block 100.

The isolation layer 115 can include insulation material, plasticmaterial, epoxy material, FR-4 material, polypropylene materials, orformex materials. The dimensions or geometry of the isolation layer 115can be selected to provide a predetermined creepage clearance or spacing(sometimes referred to as creepage-clearance specification orrequirement) between the first current collector 110 and the secondcurrent collector 120. For example, a thickness or width of theisolation layer 115 can be selected such that the first currentcollector 110 is spaced at least 3 mm from the second current collector120 when the isolation layer 115 is disposed between the first currentcollector 110 and the second current collector 120. The isolation layer115 can be formed having a shape or geometry that provides thepredetermined creepage, clearance or spacing. For example, the isolationlayer 115 can have a different dimension (e.g., length or width) thanthat the first current collector 110 and the second current collector120 such that an end or edge portion of the isolation layer 115 extendsout farther (e.g., longer) than an end or edge portion of the firstcurrent collector 110 and the second current collector 120 relative to ahorizontal plane or a vertical plane. The distance that an end or edgeportion of the isolation layer 115 extends out can provide thepredetermined creepage clearance or spacing (e.g., 3 mm creepage orclearance). The thickness and insulating structure of the isolationlayer 115, that separate the first current collector 110 and the secondcurrent collector 120, can provide the predetermined creepage, clearanceor spacing. Thus, the dimensions of the isolation layer 115 can beselected, based in part, to meet creepage-clearance specifications orrequirements. The dimensions of the isolation layer 115 can reduce oreliminate arcing between the first current collector 110 and the secondcurrent collector 120. For example, the isolation layer 115 can extendout farther than an end or edge portion of the first current collector110 and the second current collector 120 relative to a horizontal planeor a vertical plane to space the first current collector 110 and thesecond current collector 120 from each other. The isolation layer 115can have a thickness that ranges from 0.1 mm to 8 mm (e.g., 1 mm). Theisolation layer 115 can have the same width as the battery block 100.For example, the isolation layer 115 can have a width in a range from 25mm to 700 mm (e.g., 330 mm). The isolation layer 115 can have the samelength as the battery block 100. For example, the isolation layer 115can have a length in a range from 25 mm to 700 mm (e.g., 150 mm).

The material and structural configuration of the cell holders 125, 130can provide spatial separation between cells such that creepage orclearance (creepage-clearance) requirements are met or exceeded forsupporting a certain voltage across terminals of a battery pack (e.g.,400 V, or 450 V) or of a battery module 500 (e.g., 60 V) that isimplemented using the battery blocks 100. Creepage can refer to aseparation (e.g., shortest distance) between connection or weld pointsbetween (e.g., like-terminals of) battery cells 105 as measured along asurface of a bus-bar, circuit board or other connecting structure.Clearance can refer to a separation (e.g., shortest distance) betweenconnection or weld points between (e.g., like-terminals of) batterycells 105 as measured through air or space.

The first cell holder 125 and the second cell holder 130 can includeplastic material, acrylonitrile butadiene styrene (ABS) material,polycarbonate material, or nylon material (e.g., PA66 nylon) with glassfill for instance. The rigidity of first cell holder 125 and the secondcell holder 130 can correspond to the material properties forming therespective first cell holder 125 and the second cell holder 130, such asflexural modulus. The first cell holder 125 and the second cell holder130 can have a flame resistance rating (e.g., FR rating) of UL 94 ratingof V-0 or greater. For example, the UL 94 V-0 rating can correspond to awall thickness of the first cell holder 125 or the second cell holder130. The thinner the wall thickness the more difficult it can be toachieve a V-0 rating. Thus, the first cell holder 125 or the second cellholder 130 can have a thickness in a range between 0.5 mm to 2.5 mm. Thethickness of the first cell holder 125 or the second cell holder 130 canvary within or outside this range.

The first cell holder 125 and the second cell holder 130 can have adielectric strength ranging from 250V/mil to 350V/mil. For example, thefirst cell holder 125 and the second cell holder 130 can have adielectric strength of 300V/mil (other values or ranges of the valuesare possible). The first cell holder 125 and the second cell holder 130can have a tensile strength ranging from 8,000 psi to 10,000 psi. Forexample, the first cell holder 125 and the second cell holder 130 canhave a tensile strength of 9,000 psi (other values or ranges of thevalues are possible). The first cell holder 125 and the second cellholder 130 can have a flexural modulus (e.g., stiffness/flexibility)ranging from 350,000 psi to 450,000 psi. For example, the first cellholder 125 and the second cell holder 130 can have a flexural modulus(e.g., stiffness/flexibility) of 400,000 psi (other values or ranges ofthe values are possible). The values for the dielectric strength,tensile strength, or flexural modulus can vary outside these values orrange of values and can be selected based in part on a particularapplication of the first cell holder 125 and the second cell holder 130.

The first current collector 110, the isolation layer 115, the secondcurrent collector 120, the first cell holder 125, and the second cellholder 130 can be components of a battery block, battery module, orbattery pack (e.g., battery module 500 of FIG. 5). One or more of thefirst current collector 110, the isolation layer 115, the second currentcollector 120, the first cell holder 125, and the second cell holder 130(e.g., including cut-outs or apertures of any of the correspondinglayer) can be used to spatially hold or align each battery cell 105 inplace relative to other battery cells 105, to at least meetcreepage-clearance requirements of the corresponding battery pack (e.g.,to provide a voltage of at least 400 volts or other value, acrossterminals of the corresponding battery pack) and the correspondingbattery module (e.g., to provide a voltage of at least 50 volts or othervalue, across terminals of the corresponding battery module).

A single battery block 100 can include a fixed number of battery cells105 wired in parallel (“p” count) and have the same voltage with that ofthe battery cell 105, and “p” times the discharge amps. A single batteryblock 100 can be wired in parallel with one or more battery blocks 100to make a larger “p” battery block 100 for higher current applications,or wired in series as a module/unit to increase voltage. Additionally, abattery block 100 can be packaged into varying applications and can meetvarious standard battery sizes as defined by regulating bodies (e.g.,Society of Automotive Engineers (SAE), United Nations EconomicCommission for Europe (UNECE), German Institute for Standardization(DIN)) for different industries, countries, or applications.

A battery block 100 that is standardized or modularized into a buildingblock or unit, can be combined or arranged with other battery blocks 100to form a battery module (or battery pack) that can power any device orapplication, e.g., PHEV, HEV, EV, automotive, low voltage 12 voltsystem, 24 volt system, or 48 volt system, 400 volt system, 800 voltsystem, 1 kilovolt system, motorcycle/small light duty applications,enterprise (e.g., large or commercial) energy storage solutions, orresidential (e.g., small or home) storage solutions, among others.

The battery components described herein can be standardized ormodularized at the battery block level rather than at the battery modulelevel. For example, each of the battery cells 105 can be formed havingthe same shape and dimensions. Each of the battery blocks 100 can beformed having the same shape and dimensions. Battery modules can beformed having the same or different shape and dimensions. Thus, batterycells 105 can be individually replaced or additional battery cells 105can be added to increase the capacity of the respective battery block100. Battery blocks 100 can be individually replaced or additionalbattery blocks 100 can be added to increase the capacity of therespective battery module. For example, the plurality battery modulescan have a battery module capacity greater than the battery blockcapacity. Each of the plurality of battery modules can have a batterymodule voltage greater than the voltage across the battery blockterminals of the first battery block. Battery modules can beindividually replaced or additional battery modules can be added toincrease the capacity of the respective battery pack. In someapplications or embodiments, standardization or modularization at thebattery module level can be implemented instead of, or in addition tothat at the battery block level.

For example, consider the above example of a 5V/300 Ah battery block.For comparative purposes, current single battery cells of 5V/50 Ahtechnologies can be 0.03 cubic feet and six of these single cellbatteries connected in parallel would make this 0.18 cubic feet in size.This is multiple times larger than a corresponding battery blockdisclosed herein (e.g., 0.05 cubic feet). Thus, other single celltechnologies offer no volumetric advantage, and instead provide anincreased hazard or failure risk.

The battery modules or battery blocks 100 disclosed herein can overcomepackaging constraints, and can meet various performance targets usingthe same voltage of each component battery cell (0-5V) but with “p”times the discharge amps (e.g., discharge amps multiplied by the numberof cells connected in parallel in the battery block). The batterymodules (e.g., battery module 500 of FIG. 5) or battery blocks 100 canbe formed into battery packs of various size, power and energy to meetdifferent product performance requirements with the best packingefficiency and volumetric energy density that matches a specific design.

A battery block 100 can allow flexibility in the design of a batterymodule (e.g., battery module 500 of FIG. 5) or a battery pack (e.g.,battery pack 740 of FIG. 7) with initially unknown space constraints andchanging performance targets. Standardizing and using battery blocks 100(which are each smaller in size than a battery module) can decrease thenumber of parts (e.g., as compared with using individual cells) whichcan decrease costs for manufacturing and assembly. A standardizedbattery module, on the other hand, can limit the types of applicationsit can support due to its comparatively larger size and higher voltage.Standardizing battery modules with nonstandard blocks can increase thenumber of parts which can increase costs for manufacturing and assembly.In comparison, a battery block 100 as disclosed herein can provide amodular, stable, high capacity or high power device, such as a batterymodule (e.g., battery module 500 of FIG. 5) or battery pack (e.g.,battery pack 740 of FIG. 7), that is not available in today's market,and can be an ideal power source that can be packaged into variousapplications.

FIG. 2, among others, depicts an exploded view with the first currentcollector 110 and the second current collector 120. In brief overview,FIG. 2 shows a portion of the stacked configuration of layers describedin FIG. 1, that corresponds to the first current collector 110 and thesecond current collector 120. The first current collector 110 caninclude a first conductive layer that can be electrically isolated fromthe second current collector 120 by the isolation layer 115. The secondcurrent collector 120 can include a second conductive layer that canconnect to the rim 135 (around a top cap) of each of the plurality ofbattery cells 105. The top cap's rim 135 can include, provide or serveas a negative terminal of the plurality of battery cells 105.

The first current conductor 110 can couple with or connect to positiveterminals of the plurality of battery cells 105. Each of the positiveterminals can be located at a same end of a corresponding battery cell105 as a top cap rim 135 of the corresponding battery cell 105. Each ofthe first current collector 110, the second current collector 120, andthe isolation layer 115 can have a plurality of apertures 140, 145, 150configured to expose the positive terminals of the plurality of batterycells 105 through the respective layers. Portions of all or some of theapertures 140, 145, 150 are configured to conform at least in part to ashape or structure of the top cap rim 135 and the positive terminal of abattery cell 105. Each aperture 140, 145, 150 can align with two batterycells 105, two top cap rims 135, and two positive terminals, forexample.

The first current collector 110 can include the first plurality ofapertures 140 and the second current collector 120 can include the thirdplurality of apertures 150. The first plurality of apertures 140 canhave a first shape and the third plurality of apertures 150 can have asecond, different shape. The first plurality of apertures 140 and thethird plurality of apertures 150 can be formed having a shape orgeometry configured to allow the battery cells 105 to couple with orconnect from their respective surfaces to the first current collector110 and the second current collector 120. For example, the first currentcollector 110 can operate as a positive current collector layer and thesecond current collector 120 can operate as a positive current collectorlayer. Each of the battery cells 105 can be coupled with the positivefirst current collector 110 through a positive tab and coupled with thesecond current collector 120 through a negative tab.

For example, a wirebond (e.g., positive wirebond 605 of FIG. 6) canextend from a positive surface or positive portion of each of thebattery cells through the third plurality of apertures 150 and thesecond plurality of apertures 145 (as shown in FIG. 1) to couple with asecond surface (e.g., bottom surface, side surface) or portion of thefirst current collector 110, or a positive tab can extend from apositive surface or positive portion (or positive terminal) of each ofthe battery cells 105 through the third plurality of apertures 150, thesecond plurality of apertures 145 (as shown in FIG. 1), and the firstplurality of apertures 140 to couple with a first surface (e.g., topsurface, side surface) or portion of the first current collector 110.The third plurality of apertures 150, the second plurality of apertures145, and the first plurality of apertures 140 can include an insulationmaterial or insulation layer disposed around or covering the edge orside surfaces of each of their respective apertures to insulate orelectrically isolate the positive tab from the respective layer (e.g.,second current collector 120, first current collector 110). The thirdplurality of apertures 150, the second plurality of apertures 145, andthe first plurality of apertures 140 can be sized, shaped, or formed toallow for each of the battery cells 105 to couple with the first currentcollector 110.

The negative tab 205 can be formed as part of or coupled with an edge orside surface of apertures of the third plurality of apertures 150. Forexample, each of the apertures 150 of the second current collector 120can include a negative tab 205 that extends out to contact a negativesurface or portion (or terminal) of one or more battery cells 105. Thedimensions, shape, or geometry of the negative tab 205 can be selectedsuch that each negative tab 205 can couple with or contact negativesurfaces of at least two battery cells 105. The apertures 150 of thesecond current collector 120 can include a first region 210 and a secondregion 215. For example, the first region 210 and the second region 215together can form an aperture 150 of the second current collector 120.The first region 210 and the second region 215 can correspond to twoportions of a continuous open region forming an aperture 150 of thesecond current collector 120. The first region 210 and the second region215 can be formed having a variety of different dimensions, shapes, orgeometry. For example, the first region 210 and the second region 215can be formed having, but not limited to, a round shape, circular shape,square shape, or rectangular shape.

The apertures 150 of the second current collector can include tworegions 210, 215 to receive accept or receive a top portion of a batterycell 105. For example, the negative tab 205 can be disposed orpositioned between the first region 210 and the second region 215 suchthat it is coupled with (e.g., electrically coupled) or in contact withportions of a first battery cell 105 coupled with the first region 210and coupled with (e.g., electrically coupled) or in contact withportions of a second battery cell 105 coupled with the second region215. A first battery cell 105 can be disposed within the first region210 and the second battery cell 105 can be disposed within the secondregion 215. The first region 210 and the second region 215 can couplewith or contact a rim or top portion the respective battery cells 105.For example, the first region 210 and the second region 215 can alignthe rim or top portions of the respective battery cells 105 such thatthe negative tab 205 contacts at least one surface (e.g., side surface,top surface) of the respective battery cells 105 to couple the batterycells 105 with the second current collector 120.

FIGS. 3-4, among others, depict the dimensions, shapes, or geometry ofthe apertures 140, 145, 150 of the first current collector 110, theisolation layer 115, and the second current collector 120. The apertures140, 145, 150 can be formed based the shape, dimensions, or geometry ofeach other and to provide appropriate spacing to allow for the batterycells 105 to couple with the first current collector 110 and the secondcurrent collector 120. For example, the shape, dimensions, or geometryof the apertures 140, 145, 150 can be selected such that when the firstcurrent collector 110, the isolation layer 115, and the second currentcollector 120 are coupled with each other or stacked onto each other,the apertures 140, 145, 150 are aligned to allow at least two batterycells 105 to couple with at least one negative tab 205 of the secondcurrent collector 120 and at least one battery cell 105 to couple withthe first current collector 110 through a positive tab of the at leastone battery cell 105. As depicted in FIG. 3, the first current collector110 is coupled with or disposed over the isolation layer 115 and theisolation layer 115 is coupled with or disposed over the second currentcollector 120. In this example arrangement, the third plurality ofapertures 150 are aligned with the first and second plurality ofapertures 140, 145 such that the negative tabs 205 extend out in agenerally middle portion of each of the apertures 140, 145, 150 betweenthe first region 210 and the second region 215. Thus, when a firstbattery cell 105 is coupled with or disposed in the first region 210 anda second battery cell 105 is coupled with or disposed in the secondregion 215, a portion or surface of each of the first battery cell 105and the second battery cell 105 can couple with or contact the negativetab 205 and have proper clearance or spacing to allow for a firstpositive tab of the first battery cell 105 to couple the first batterycell 105 with the first current collector 110 and a second positive tabof the second battery cell 105 to couple the second battery cell 105with the first current collector 110.

The first plurality of apertures 140 can have a different shape,dimensions, or geometry from the second plurality of apertures 145 orthe third plurality of apertures 150. The shape, dimensions, or geometryof the first plurality of apertures 140 can be the same or similar tothe second plurality of apertures 145 and different than the shape,dimensions, or geometry of the third plurality of apertures 150. Theisolation layer 115 can include a creepage portion 305 that extends fromone or more edges or side surfaces of the isolation layer 115. Thecreepage portion 305 can have a predetermined length to extend beyondone or more edges or side surfaces of the isolation layer 115 to space,separate or distance the first collector 110 from the second collector120 by a predetermined creepage clearance or spacing. The creepageportion 305 can have a predetermined thickness to space the firstcollector 110 from the second collector 120 at a predetermined creepageclearance or spacing. For example, a thickness or width of the creepageportion 305 can be selected such that the first current collector 110 isspaced at least 3 mm from the second current collector 120 when theisolation layer 115 is disposed between the first current collector 110and the second current collector 120. The predetermined creepageclearance can include a range from 1 mm to 5 mm (e.g., 3 mm). Thus, thedimensions of the creepage portion 305 can be selected, based in part,to meet creepage clearance specifications or requirements. Thedimensions of the creepage portion 305 can reduce or eliminate arcingalong an insulating surface between the first current collector 110 andthe second current collector 120.

The creepage portion 305 can be formed in the same plane as theisolation layer 115. For example, the creepage portion 305 can be formedhaving a straight shape such that it extends out parallel with respectto a surface or plane of the isolation layer. The creepage portion 305can be formed or coupled with one edge or side surface of the isolationlayer 115 or the creepage portion 305 can be formed or coupled withmultiple edges or multiple side surfaces of the isolation layer 115(e.g., two sides, three sides, all sides). The isolation layer 115 caninclude or be formed as an injection molded plastic piece that formsaround either the first current collector 110 or second currentcollector 120 to provide the predetermine creepage clearance. Forexample, the plastic piece can be formed to provide creepage protectionnot only for the parallel extension from the respective conductive layer(e.g., first current collector 110, second current collector 120), butcan also increase a height (or thickness) of the respective conductivelayer (e.g., first current collector 110, second current collector 120).A coating (e.g., powder coating, anodizing, conformal coating, or otherspray coating) can be applied to one or more edge surfaces of theisolation layer 115, first current collector 110, or second currentcollector 120 to coat the respective edges and unbonded (where noelectrical connection is made) areas. The coating can be used inconjunction with the parallel extension of isolation layer 115 or can beused instead of the parallel extension of isolation layer 115.

FIG. 11 depicts a view of the spatial relationship between the positivecurrent collector 110, the isolation layer 115, and the negative currentcollector 120 relative to a battery cell 105. As depicted in FIG. 11,the isolation layer 115 extends beyond one or more edges or sidesurfaces of the first current collector 110 and the second currentcollector 120 to space, separate or distance the first collector 110from the second collector 120 by a predetermined creepage clearance orspacing. The portion of the isolation layer 115 that extends out beyondone or more edges or side surfaces of the first current collector 110and the second current collector 120 may be the same as the creepageportion 305 described above with respect to FIG. 3. For example, theisolation layer 115 can include a creepage portion having apredetermined length to space, separate or distance the first collector110 from the second collector 120 by a predetermined creepage clearanceor spacing. The creepage portion 305 of the isolation layer 115 can havea predetermined thickness to space the first collector 110 from thesecond collector 120 at a predetermined creepage clearance or spacing.The predetermined creepage clearance can include a range from 1 mm to 5mm (e.g., 3 mm). Thus, the dimensions of the creepage portion of theisolation layer 115 can be selected, based in part, to meet creepageclearance specifications or requirements. The dimensions of the creepageportion of the isolation layer 115 can reduce or eliminate arcing alongan insulating surface between the first current collector 110 and thesecond current collector 120. For example, the isolation layer 115 canextend out farther than an end or edge portion of the first currentcollector 110 and the second current collector 120 relative to ahorizontal plane or a vertical plane to space the first currentcollector 110 and the second current collector 120 from each other adistance corresponding to creepage clearance specifications orrequirements.

Referring to FIG. 3, among others, the positive current collector 110and the negative current collector 120 can be electrically conductiveand can be laminated together with the isolation layer 115 (e.g.,nonconductive layer) disposed between the positive current collector 110and the negative current collector 120. For example, FIG. 3 shows anembodiment of the stacked configuration of current collectors, inisometric view. In this view, the positive current collector 110 and thenegative current collector 120 are shown laminated together, as opposedto the exploded view in FIG. 2.

FIG. 4, among others, depicts a top view of the stacked configuration ofcurrent collectors, including portions of the positive current collector110, exposed portions of the negative current collector 120, and theapertures 140, 150 of the first current collector 110 and the secondcurrent collector 120, respectively, is provided. The isolation layer115 can enable or support the lamination, and can include an isolationmaterial or insulation material having high dielectric strength that canprovide electrical isolation between the first current collector 110 andthe second current collector 120. The isolation layer 115, including alamination layer or lamination material, can hold the first currentcollector 110 and the second current collector 120 together. Thelamination layer can provide a conformal coating that is disposed overone or more of the first current collector 110, the isolation layer 115,or the second current collector 120, and can protect against shortingfrom the first current collector 110 (e.g., positive current collector)and the second current collector 120 (e.g., negative currentcollectors). The lamination layer can be disposed such that weld areas(e.g., for welding to battery cell terminals) are not covered, or remainexposed to allow electrical connections. This design can supportdifferent weld or bonding techniques, such as wire bonding or laserwelding (e.g., for the negative connections).

Using the single sided weld approach discussed herein, the positiveterminal connections to the first current collector 110 and the negativeterminal connections to the second current collector 120 can be madefrom the same end of the battery cell 105 at which the top cap islocated. The rim 135, edge or other portion of the top cap assembly canform or provide a negative terminal and can be welded to a currentcollector for negative collections. Welding can be performed to forexample a narrow and non-flat (protruded) profile of the rim at the topcap (e.g., along the round edge that extends into the cylindricalsurface of the battery cell), to connect the negative terminal to aportion of a current collector for negative collections. For example,welding can be performed to connect the negative terminal to an apertureedge (e.g., of a tabbed or protruded portion of the aperture), or anupper surface portion (e.g., of a tabbed or protruded portion of theaperture) of the current collector (e.g., negative current collector120) for negative collections. The positive terminal tab portion of thetop cap can connect to a portion of a current collector (e.g., firstcurrent collector 110) for positive collections. For example, weldingcan be performed to an aperture edge or top surface portion of thecurrent collector for positive collections. Hence, in accordance withthe concepts disclosed herein, a current collector configuration isprovided that can support positive and negative weld connections at thetop cap end, that can support one or more methods for welding, that cansupport tool access (e.g., for welding, assembly), and that can provideisolation between the negative and positive current collectors.

Referring for example to FIGS. 1-4, the bottom layer of the first cellholder 125 can incorporate, be physically coupled with, or expose anegative current collector or second current collector 120, partially orotherwise. The second current collector 120 can be made of a thinconductive metal (e.g., of less than 5 mm in thickness, although otherdimensions are possible). The second current collector 120 can be madeof or include a metal, such as but not limited to, copper or aluminum,and can be affixed or mounted (e.g., directly) on a battery cell 105.The second current collector 120 can be designed or implemented withprecise cut-outs or apertures 150 where a wirebond head can touch therim 135 of the battery cell 105 and bond to the second current collector120. The second current collector 120 can be designed or implementedwith partial cut-outs or partially-formed apertures 150 at or along oneor more edges of the layer, to expose at least one positive terminal ofthe battery cells 105 through the layer. The second current collector120 can be designed or implemented to support resistive welding forinstance, in which a bondhead can contact the second current collector120 directly and weld to the rim 135 to make a negative terminalconnection.

The isolation layer 115 can be disposed or stacked above the secondcurrent collector 120 to provide isolation from the first currentcollector 110 (e.g., positive current collector). The first currentcollector 110 can comprise a thin conductive metal (e.g., of less than 5millimeter in thickness, although other dimensions are contemplated) ormetal layer. The first current collector 110 can be made of a metal suchas copper or aluminum, and can be affixed or mounted (e.g., directly) ona battery cell 105. The first current collector 110 can be designed orimplemented with precise cut-outs or apertures 140 whereby a positiveterminal connection can be made by welding from the positive tab portionto the first current collector 110 (e.g., a top surface portion of thefirst current collector 110, or an edge surface portion of acorresponding aperture 140). The first current collector 110 can bedesigned or implemented with partial cut-outs or partially-formedapertures 140 at or along one or more edges of the layer, to expose atleast one positive terminal of the battery cells 105 through the layer.The stacked configuration can incorporate protective features includingchannels, routing vents, cutouts or apertures 140, 145, 150 in the firstcurrent collector 110, the second current collector 120, or theisolation layer 115, for vent gasses to escape through the top (e.g., tosupport certain types of battery cells 105, such as bottom vent cells).

The apertures 140, 150 (or cutouts) in the first current collector 110or the second current collector 120 can be created to enable specificconnections to a battery cell rim or tab region. For instance, theapertures 150 of the second current collector 120 can each have an areasmaller than that of a corresponding aperture 140 of the positivecurrent collector 110. For example, as shown in FIG. 4, each aperture150 of the second current collector 120 can have a smaller area (thanthat of a corresponding aperture of the first current collector 110) dueto an edge, tabbed portion, or negative tab 205 protruding towards acenter of the respective aperture 150 (and partially conforming to acircular or curved boundary of each of the regions 210, 215). A portionof the second current collector 120 proximate to or on a portion of thenegative tab 205 (e.g., the curved portion of the edge) can be designedor configured to be welded or bonded to a corresponding negativeterminal (or rim region 135) of a battery cell 105. A region proximateto or on a curved portion or edge of a corresponding aperture 140 of thefirst current collector 110 (that is away from, or that does notcoincide with the above portion of the second current collector 120, forinstance), can be welded or bonded to a corresponding positive terminal(or tab region). To provide electrical isolation, certain portions ofthe apertures 140, 150 of the first current collector 110 or secondcurrent collector 120 can have aperture edges that are electricallyisolated (e.g., via a nonconductive coating) from the positive terminalsof the plurality of battery cells 105, or from the wirebond or weld.

The first current collector 110 and the second current collector 120(e.g., the positive and negative current collectors) can be incorporatedinto a single part or component. For example, the first currentcollector 110 and the second current collector 120 can include a layereddevice and a laminated device incorporated or otherwise formed into asingle part or component. Such a design can enable a single sided, topweld approach for cylindrical battery cells 105 to make electricalconnections from one battery cell 105 to another from the top cap side.Single sided welding for positive and negative connections can becomparatively easier to handle or perform than the dual sided approach,by simplifying assembly processes for battery blocks or modules (e.g.,battery blocks 100 and battery modules 500 of FIG. 5). A single part,stacked current collector structure can improve battery cell 105 tobattery cell 105 interconnection design, for instance by decreasing thenumber of parts for connecting to battery cells 105, and isolating firstcurrent collector 110 and second current collector 120 while holdingthese together. Laminating current collectors in such a configurationcan protect against shorting by limiting exposed areas to those forwelding for instance. The stacked current collector configuration canincorporate additional cutouts to allow vent gas to escape from the top.

Aspects of stacked conductive layers are discussed herein by way ofexample. Instead of stacked layers (e.g., in the z direction), a firstor positive current collector 110 can comprise strips of conductorsarranged in a parallel configuration along a first direction (e.g., inthe x direction), and a second or negative current collector 120 cancomprise strips of conductors arranged in a parallel configuration alonga second direction (e.g., in the y direction) different from the firstdirection. In addition, the design of the current collectors can beadjusted to support different welding strategies, such as those otherthan wirebond, laser or resistive welding.

FIG. 5, among others, depicts an example system to power electricvehicles. In FIG. 5, a battery module 500 is provided having two batteryblocks 100 (e.g., a first battery block 100 and a second battery block100). The first and second battery blocks 100 can be subcomponents ofthe battery module 500. A battery module 500 as described herein canrefer to a battery system having multiple battery blocks 100 (e.g., twoor more). Multiple battery blocks 100 can be electrically coupled witheach other to form a battery module 500. For example, a high-torquemotor may be suitably powered by a battery module 500 formed withmultiple battery blocks 100, each battery block 100 having multiplebattery cells 105 (e.g., 500 cells). The battery blocks 100 or batterymodules 500 can couple in parallel to increase capacity and to increasecurrent values (e.g., in Amperes or amps) that can be discharged. Abattery block 100 can be formed with 20 to 50 battery cells 105, forinstance, and can provide a corresponding number of times the capacityof a single battery cell 105.

The battery modules 500 can be formed having a variety of differentshapes. For example, the shape of the battery modules 500 can bedetermined or selected to accommodate a battery pack within which arespective battery module 500 is to be disposed. The shape of thebattery modules 500 may include, but not limited to, a square shape,rectangular shape, circular shape, or a triangular shape. Batterymodules 500 in a common battery pack can have the same shape. One ormore battery modules 500 in a common battery pack can have a differentshape from one or more other battery modules 500 in the common batterypack. Battery blocks 100 can be held together using one or more cellholders 125, 130. For example, a single one of cell holders 125, 130 canhouse at least two battery blocks 100 in a single plastic housing. Thebattery cells 105 can be positioned within the respective one of thecell holder 125, 130 using adhesive material (e.g., 2-part epoxy,silicone-based glue, or other liquid adhesive), heat staking, or pressfit. The battery cells 105 can be positioned within the respective oneof the cell holder 125, 130 to hold them in place. For example, thebattery cells 105 can have a tolerance in height as part of themanufacturing process. This tolerance can be accounted for by locatingeither the top or bottom of the respective battery cells 105 to a commonplane and fixing them there within the respective one of the cell holder125, 130. For example, a bottom end of each of the battery cells 105 canbe positioned flat relative to each other to provide a flat matingsurface to a cold plate. The top end of the battery cells 105 can bepositioned flat relative to the first cell holder 125 to provide or forma flat plane for forming battery cell to current collector connections(e.g., wirebonding, laser welding). The flat plane may only be providedon a top or bottom plane of the battery cells 105 because the cellholders 125, 130 can be retained in the respective battery module 500using adhesive material (e.g., 2-part epoxy, silicone-based glue, orother liquid adhesive), bolts/fasteners, pressure sensitive adhesive(PSA) tape, or a combination of these materials. The structure of thebattery module 500 that the cell holders 125, 130 are placed in ordisposed in can include a stamped, bent, or formed metal housing orcould be a plastic housing made by injection molding or anothermanufacturing method.

The number of battery blocks 100 in a battery module 500 can vary andcan be selected based at least in part on an amount of energy or powerto be provided to an electric vehicle. For example, the battery module500 can couple with one or more bus-bars within a battery pack or couplewith a battery pack of an electric vehicle to provide electrical powerto other electrical components of the electric vehicle. The batterymodule 500 includes multiple battery blocks 100. The battery module 500can include multiple cell holders 125, 130 to hold or couple the batteryblocks 100 together, and to couple the battery cells 105 to form thebattery blocks 100 together. The first and second battery blocks 100include a plurality of battery cells 105. The battery cells 105 can behomogeneous or heterogeneous in one or more aspects, such as height,shape, voltage, energy capacity, location of terminal(s) and so on. Thefirst battery block 100 may include the same number of battery cells 105as the second battery block 100, or the first battery block 100 may havea different number of battery cells 105 (e.g., greater than, less than)the second battery block 100. The first and second battery blocks 100can include any number of battery cells 105 arranged in anyconfiguration (e.g., an array of N×N or N×M battery cells, where N, Mare integers). For example, a battery block 100 may include two batterycell 105 or fifty battery cells 105. The number of battery cells 105included within a battery block 100 can vary within or outside thisrange. The number of battery cells 105 included within a battery block100 can vary based in part on battery cell level specifications, batterymodule level requirements, battery pack level requirements or acombination of these that you are trying to obtain or reach with therespective battery block 100. The number of battery cells 105 to includein a particular battery block 100 can be determined based at least inpart on a desired capacity of the battery block 100 or a particularapplication of the battery block 100. For example, a battery block 100can contain a fixed “p” amount of battery cells, connected electricallyin parallel which can provide a battery block capacity of “p” times thatof the single battery cell capacity. The voltage of the respectivebattery block 100 (or cell block) can be the same as that of the singlebattery cell 105 (e.g., 0V to 5V or other ranges), which could betreated as larger cells that can be connected in series into the batterymodule 500 for battery packs for example. For example, the plurality ofcylindrical battery cells 105 can provide a battery block capacity tostore energy that is at least five times greater than a battery cellcapacity of each of the plurality of cylindrical battery cells 105. Thebattery blocks 100 can have a voltage of up to 5 volts across the pairof battery block terminals of the respective battery block 100.

The battery blocks 100 can each include one or more battery cells 105and each of the plurality of battery cells 105 can have a voltage of upto 5 volts (or other limit) across terminals of the correspondingbattery cell 105. For example, the battery blocks 100 can include anarrangement of a plurality of battery cells 105 electrically connectedin parallel. Each cell of the plurality of battery cells 105 can bespatially separated from each of at least one adjacent cell 105 by, forexample, two millimeter (mm) or less. The arrangement of the pluralityof battery cells 105 can form a battery block 100 for storing energy andcan have a voltage of up to 5 volts across terminals of the respectivebattery block 100.

For instance, a single battery cell 105 can have a maximum voltage of4.2V, and the corresponding battery block 100 can have a maximum voltageof 4.2V. By way of an example, a battery block 100 using 5 volts/5Ampere-hour (5V/5 Ah) cells with 60 cells in parallel can become a 0V to5V, 300 Ah modular unit. The battery block 100 can have high packagingefficiency by utilizing the minimum cell to cell spacing (e.g., anyvalue from 0.3 mm to 2 mm) that prevents thermal propagation within theblock with each cell having an individual and isolated vent port forinstance. For example, spatial separation between adjacent cells of lessthan 1 mm can be implemented in the present battery blocks 100. Thebattery block 100 can thus be small, e.g., less than 0.05 cubic feet,giving it a high volumetric energy density for high packing efficiency.

The battery block 100 can include battery cells 105 physically arrangedin parallel to each other along the longest dimension of each batterycell 105. The battery cells 105 can be arranged physically as a twodimensional array of battery cells 105, or can be arranged physically asa three dimensional array of battery cells 105. For example, the batterycells 105 can be arranged in an array formation having three values,such as a length value 550, a height value (or depth value) 555, and awidth value 560 to form the battery block 100 and form battery module500. As depicted in FIG. 5, the battery module 500 can have a dimensionof length 550×width 560×height 555. The battery module 500 can have alength value 550 of 200 mm, a width value 560 of 650 mm, and a heightvalue 555 of 100 mm. The length 550 may range from 25 mm to 700 mm. Thewidth 560 may range from 25 mm to 700 mm. The height 555 (or depth) mayrange from 65 mm to 150 mm. The height 555 of the battery module 500 orthe battery blocks 100 may correspond to (or be dictated by) the heightor longest dimension of a component the battery cell 105.

The battery blocks 100 may form or include an enclosure or housing. Forexample, the plurality of battery cells 105 can be enclosed in a batteryblock enclosure. The battery block enclosure can be formed in a varietyof different shapes, such as but not limited to, a rectangular shape, asquare shape or a circular shape. The battery block enclosure can beformed having a tray like shape and can include a raised edge or borderregion. The battery cells 105 can be held in position by the raised edgeor border region of the battery block enclosure. The battery blockenclosure can be coupled with, in contact with, or disposed about theplurality of battery cells 105 to enclose the plurality of battery cells105. For example, the battery block enclosure can be formed such that itat least partially surrounds or encloses each of the battery cells 105.The battery block enclosure can be less than 1 cubic feet in volume. Forexample, the battery block enclosure can be less than 0.05 cubic feet involume.

The battery cells 105 can be provided or disposed in the first andsecond battery blocks 100 and can be arranged in one or more rows andone or more columns of battery cells 105. Each of the rows or columns ofbattery cells 105 can include the same number of battery cells 105 orthey can include a different number of battery cells 105. The batterycells 105 can be arranged spatially relative to one another to reduceoverall volume of the battery block 100, to allow for minimum cell tocell spacing (e.g., without failure or degradation in performance), orto allow for an adequate number of vent ports. The rows of battery cells105 can be arranged in a slanted, staggered or offset formation relativeto one another. The battery cells 105 can be placed in various otherformations or arrangements.

Each of the battery cells 105 in a common battery block 100 (e.g., samebattery block 100) can be spaced from a neighboring or adjacent batterycell 105 in all directions by a distance that ranges from 0.5 mm to 3 mm(e.g., 1.5 mm spacing between each battery cell 105, 2 mm spacingbetween each battery cell 105). The battery cells 105 in a commonbattery block 100 can be uniformly or evenly spaced. For example, eachof the battery cells 105 can be spaced the same distance from one ormore other battery cells 105 in the battery blocks 100. One or morebattery cells 105 in a common battery block 100 can be spaced one ormore different distances from another one or more battery cells 105 ofthe common battery block 100. Adjacent battery cells 105 betweendifferent battery blocks 100 can be spaced a distance in a range from 2mm to 6 mm. The distances between the battery cells 105 of differentbattery blocks 100 can vary across applications and configurations, andcan be selected based at least in part on the dimensions of the batteryblocks 100, electrical clearance or creepage specifications, ormanufacturing tolerances for the respective battery module 500.

The battery block 100 can provide a battery block capacity of up to 300Ampere-hour (Ah) or more. The battery block 100 can provide varyingcapacity values. For example, the battery block 100 can provide acapacity value that corresponds to a total number of cylindrical batterycells 105 in the plurality of cylindrical battery cells 105 forming therespective battery block 100. For example, the battery block 100 canprovide a battery block capacity in a range from 8 Ah to 600 Ah.

The battery blocks 100 can be formed having a variety of differentshapes. For example, the shape of the battery blocks 100 can bedetermined or selected to accommodate a battery module 500 or batterypack within which a respective battery block 100 is to be disposed. Theshape of the battery blocks 100 may include, but not limited to, asquare shape, rectangular shape, circular shape, or a triangular shape.Battery blocks 100 in a common battery module 500 can have the sameshape, or one or more battery blocks 100 in a common battery module 500can have a different shape from one or more other battery blocks 100 inthe common battery module 500.

The battery blocks 100 can each include at least one cell holder 125,130 (sometimes referred as a cell holder). For example, the first andsecond battery blocks 100 can each include a first cell holder 125 and asecond cell holder 130. The first cell holder 125 and the second cellholder 130 can house, support, hold, position, or arrange the batterycells 105 to form the first or second battery blocks 100 and may bereferred to herein as structural layers. For example, the first cellholder 125 and the second cell holder 130 can hold the battery cells 105in predetermined positions or in a predetermined arrangement to providethe above described spatial separation (e.g., spacing) between each ofthe battery cells 105. The first cell holder 125 can couple with or bedisposed on or over a top surface of each of the battery cells 105. Thesecond cell holder 130 can couple with or contact a bottom surface ofthe each of the battery cells 105.

The first cell holder 125 and the second cell holder 130 can include oneor more recesses, cutouts or other forms of holes or aperturesconfigured to hold portions of the battery cells 105. The recesses,cutouts or other forms of holes or apertures of the first and secondcell holders 125, 130 can be formed to conform or match with, orcorrespond to the dimensions of the battery cells 105. For example, eachof the recesses, cutouts or other forms of holes or apertures can havethe same dimensions (e.g., same diameter, same width, same length) aseach of the battery cells 105 to be disposed within the respectiverecess, cutout, or other forms of holes or apertures. The battery cells105 can be disposed within the recesses, cutouts or other forms of holesor apertures such that they are flush with an inner surface of therecesses, cutouts or other forms of holes or apertures. For example, anouter surface of each of the battery cells 105 can be in contact withthe inner surface of the recesses, cutouts or other forms of holes orapertures of each of the first and second cell holders 125, 130 when thebattery cells 105 are disposed within or coupled with the recesses,cutouts or other forms of holes or apertures of each of the first andsecond cell holders 125, 130.

The battery module 500 can include a single battery block 100 ormultiple battery blocks 100 (e.g., two battery blocks 100, or more thantwo battery blocks 100). The number of battery blocks 100 in a batterymodule 500 can be selected based at least in part on a desired capacity,configuration or rating (e.g., voltage, current) of the battery module500 or a particular application of the battery module 500. For example,a battery module 500 can have a battery module capacity that is greaterthan the battery block capacity forming the respective battery module500. The battery module 500 can have a battery module voltage greaterthan the voltage across the battery block terminals of the battery block100 within the respective battery module 500. The battery blocks 100 canbe positioned adjacent to each other, next to each other, stacked, or incontact with each other to form the battery module 500. For example, thebattery blocks 100 can be positioned such that a side surface of thefirst battery block 100 is in contact with a side surface of the secondbattery block 100. The battery module 500 may include more than twobattery blocks 100. For example, the first battery blocks 100 can havemultiple side surfaces positioned adjacent to or in contact withmultiple side surfaces of other battery blocks 100. Various types ofconnectors can couple the battery blocks 100 together within the batterymodule 500. The connectors may include, but not limited to, straps,wires, ribbonbonds, adhesive layers, or fasteners. The electricalconnections between battery blocks 100 and battery modules 500 can usealuminum or copper busbars (stamped/cut metallic pieces in variousshapes) with fasteners, wires and ribbons (aluminum, copper, orcombination of the two), press fit studs and connectors with coppercables, or bent/formed/stamped copper or aluminum plates.

FIG. 6, among others, depicts a top view of the battery module 500illustrating an example arrangement of the battery cells 105 in each ofthe first battery block 100 and the second battery block 100. Thebattery blocks 100 can include a pair of terminals 620, 625. Forexample, the battery blocks 100 include a first battery block terminal620 and a second battery block terminal 635. The first battery blockterminal 620 can correspond to a positive terminal and the secondbattery block terminal 625 can correspond to a negative terminal Theplurality of cylindrical battery cells 105 can provide a battery blockcapacity to store energy that is at least five times greater than abattery cell capacity of each of the plurality of cylindrical batterycells 105. The battery blocks 100 can have a voltage of up to 5 voltsacross the pair of battery block terminals 620, 625. For example, thefirst battery block terminal 620 can be coupled with 5 V and the secondbattery block terminal 625 can be coupled with 0 v. The first batteryblock terminal 620 can be coupled with +2.5 V and the second batteryblock terminal 625 can be coupled with −2.5 V. Thus, a difference involtage between the first battery block terminal 620 and the secondbattery block terminal 625 can be 5 V or up to 5 V.

The battery cells 105 in the first and second battery blocks 100 can bearranged in one or more rows and one or more columns of battery cells105. The individual battery cells 105 can be cylindrical cells or othertypes of cells. Depending on the shape of each battery cell 105, thebattery cells 105 can be arranged spatially relative to one another toreduce overall volume of the battery block 100, to minimize cell to cellspacing (e.g., without failure or degradation in performance), or toallow for an adequate number of vent ports. For instance, FIG. 6, amongothers, shows each row of battery cells 105 arranged in a slanted oroffset formation relative to one another. The battery cells 105 can beplaced in various other formations or arrangements.

The battery cells 105 in a common battery block 100 can be uniformlyspaced, evenly spaced or one or more battery cells 105 in a commonbattery block 100 can be spaced one or more different distances fromanother one or more battery cells 105 of the common battery block 100.Each of the battery cells 105 in a common battery block 100 (e.g., samebattery block 100) can be spaced from a neighboring or adjacent batterycell 105 in all directions by a distance that ranges from 0.5 mm to 3 mm(e.g., 1.5 mm spacing between each battery cell 105, 2 mm spacingbetween each battery cell 105). For example, a first battery cell 105can be spaced a distance of 1.5 mm from a neighboring second batterycell 105 and spaced a distance of 1.5 mm from a neighboring thirdbattery cell 105. The battery cells 105 in a common battery block 100can be uniformly spaced, or evenly spaced. One or more battery cells 105in a common battery block 100 can be spaced one or more differentdistances from another one or more battery cells 105 of the commonbattery block 100. Depending on the shape of each battery cell 105, thebattery cells 105 can be arranged spatially relative to one another toreduce overall volume of the battery block 100, to allow for minimumcell to cell spacing (e.g., without failure or degradation inperformance), or to allow for an adequate number of vent ports. Forinstance, each row of battery cells 105 can be arranged in a slanted oroffset formation relative to one another. The battery cells 105 can beplaced in various other formations or arrangements.

The battery cells 105 (e.g., adjacent battery cells 105) betweendifferent battery blocks 100 (e.g., adjacent battery blocks 100) can bespaced a distance in a range from 2 mm to 6 mm. For example, one or morebattery cells 105 disposed along an edge of a first battery block 100can be spaced a distance in a range from 0 mm to 1 mm (e.g., 0.5 mm)from the edge of the first battery block 100 and one or more batterycells 105 disposed along an edge of a second battery block 100 can bespaced a distance in a range from 0 mm to 1 mm (e.g., 0.5 mm) from theedge of the second battery block 100. The edges of the first and secondbattery blocks 100 can be coupled with each other, in contact with eachother, or facing each other such that the one or more battery cells 105disposed along the edge of the first battery block 100 are spaced fromthe one or more battery cells 105 disposed along the edge of the secondbattery block 100 a distance in a range from 2 mm to 6 mm (e.g., 4.5mm). The distances between the battery cells 105 of different batteryblocks 100 can vary and can be selected based at least in part on thedimensions of the battery blocks 100, electrical clearance or creepagespecifications, or manufacturing tolerances for the respective batterymodule 500. For example, battery cells 105 can be spaced a distance froma second, different battery cell 105 based on predeterminedmanufacturing tolerances that may control or restrict how close batterycells 105 can be positioned with respect to each other.

The battery cells 105 can each couple with a first layer 110 (e.g.,positive conductive layer) of the first cell holder 125. For example,the first cell holder 125 can include multiple layers, such as, a firstlayer forming a positive current collector 110, an isolation layerhaving non-conductive material 115, and a second layer forming negativecurrent collector 120. Each of the battery cells 105 can include a pairof battery cell terminals 620, 625. For example, the battery cells 105can include a positive terminal 620 and a negative terminal 625. Thepair of terminals 620, 625 of each of the battery cells 105 can have upto 5 V across their respective terminals. For example, the positiveterminal 620 can be coupled with +5 V and the negative terminal 625 canbe coupled with 0 V. The positive terminal 620 can be coupled with +2.5V and the negative terminal 625 can be coupled with −2.5 V. Thus, thedifference in voltage between the positive terminal 620 and the negativeterminal 625 of each battery cell 105 can be 5 V or in any value up toand including 5 V.

The positive terminal 620 of a battery cell 105 can be connected using awirebond 605 or otherwise, with the first layer of the first cell holder125. The negative terminal 625 or negative surface of a battery cell 105can connect with the second layer of the first cell holder 125 through anegative tab 205. The positive terminal 620 and the negative terminal625 of a battery cell 105 can be formed on or coupled with at least aportion of the same surface (or end) of the respective battery cell 105.For example, the positive terminal 620 can be formed on or coupled witha first surface (e.g., top surface, side surface, bottom surface) of thebattery cell 105 and the negative terminal 625 of the battery cell 105can be formed on or coupled with the same first surface. Thus, theconnections to positive and negative bus-bars or current collectors canbe made from the same surface (or end) of the battery cell 105 tosimplify the installation and connection of the battery cell 105 withina battery block 100.

The negative tab 205 can couple at least two battery cells 105 with aconductive negative layer 120 of the first cell holder 125. The negativetab 205 can be part of the conductive negative layer 120, for exampleformed as an extension or structural feature within a plane of theconductive negative layer 120, or partially extending beyond the plane.The negative tab 205 can include conductive material, such as but notlimited to, metal (e.g., copper, aluminum), or a metallic alloy ormaterial. The negative tab 205 can form or provide a contact point tocouple a battery cell 105 to a negative current collector 120 of thefirst cell holder 125. The negative tab 205 can couple with or contact atop portion or top surface (e.g., negative terminal 625) of the batterycell 105. The negative tab 205 can couple with or contact a side surfaceof a battery cell 105. The negative tab 205 can couple with or contact abottom portion or bottom surface of a battery cell 105. The surface orportion of a battery cell 105 the negative tab 205 couples with orcontacts can correspond to the placement of the first cell holder 125relative to the battery cell 105.

The negative tab 205 can have a shape configured to couple with orcontact surfaces of at least two battery cells 105. The negative tab 205can be formed in a variety of different shapes and have a variety ofdifferent dimensions (e.g., conformed to the dimensions of the batterycells 105 and their relative positions). The shape of the negative tab205 can include, but not limited to, rectangular, square, triangular,octagon, circular shape or form, or one or more combinations ofrectangular, square, triangular, or circular shape or form. For example,the negative tab 205 can be formed having one or more sides (e.g.,portions or edges) having a circular or curved shape or form to contacta surface of the battery cells and one or more sides having a straightor angled shape. The particular shape, form or dimensions of thenegative tab 205 can be selected based at least in part on a shape, formor dimensions of the battery cells 105 or a shape, form or dimensions ofthe first cell holder 125. The shape and structure of the negative tab205 can be formed in two or three dimensions. For example, one or moreedges or portions of the negative tab 205 can be folded or formed into ashape or structure suitable for bonding to a negative terminal portionof a battery cell 105. For a two-dimensional negative tab 205 (e.g., anegative tab 205 with a thickness conformed with a thickness of thecorresponding conductive negative layer), the negative tab 205 caninclude or be described with one or more parameters, such as length, awidth, surface area, and radius of curvature. For a three-dimensionalnegative tab 205 (e.g., a negative tab 205 with at least a portion thatdoes not conform with a thickness of the corresponding conductivenegative layer), the negative tab 205 can include or be described withone or more parameters, including length, width, height (or depth,thickness), one or more surface areas, volume, and radius of curvature.The three-dimensional negative tab 205 can include a folded, curved oraccentuated portion that provides a larger surface for a negativesurface of a battery cell 105 to couple with or contact. For example,the three-dimensional negative tab 205 can have a greater thickness thana two-dimensional negative tab 205.

The wirebond 605 can be a positive wirebond 605 that can couple at leastone battery cell 105 with a conductive positive layer 110 of the cellholder 125. The wirebond 605 can be formed in a variety of differentshapes and have a variety of different dimensions. The particular shapeor dimensions of wirebond 605 can be selected based at least in part ona shape or a dimension of the battery cells 105 or a shape or adimension of the first cell holder 125. For example, the wirebond 605can be sized to extend from a top surface, side surface or bottomsurface of a battery cell 105. As depicted in FIG. 6, the wirebond 605can extend from a top surface (e.g., a positive terminal 620) of abattery cell 105 and extend through apertures 140, 145, 150 formed ineach of the different layers forming the first cell holder 125, tocontact a top surface of the conductive positive layer of the cellholder 125. The shape of the wirebond 605 can be selected or implementedso as not to contact a negative layer of the first cell holder 125 asthe wirebond 605 extends through the different layers forming the firstcell holder 125. The shape or form of the wirebond 605 can include arectangular shape, cylindrical shape, tubular shape, spherical shape,ribbon or tape shape, curved shape, flexible or winding shape, orelongated shape. The wirebond 605 can include electrical conductivematerial, such as but not limited to, copper, aluminum, metal, ormetallic alloy or material.

FIG. 10, among others, depicts a top view of the battery module 500illustrating coated surfaces 1005 and exposed surfaces 1010 of the firstbattery block 100 and the second battery block 100. The first and secondbattery blocks 100 can include the multi-layered current collectorhaving a positive current collector 110, an isolation layer 115, and anegative current collector 120. The multi-layered current collector canbe laminated to protect against shorting by only exposing areas forwelding, bonding or connecting to terminals of a battery cell 105. Forexample, each of the positive current collector 110, the isolation layer115, and the negative current collector 120 can include apertures orcutouts to allow vent gas to escape, such as, to escape or vent from atop portion of a battery cell 105 for instance, through one or moreapertures of each of the different layers (e.g., positive currentcollector 110, isolation layer 115, negative current collector 120). Thecoated surfaces 1005 can include surfaces of the respective batteryblocks 100 that are laminated or coated with a laminate material oradhesive material. Surfaces of the battery blocks 100 that are not to beused for welding, bonding or connecting to terminals of battery cells105. The exposed surfaces 1010 can correspond to surfaces of the batteryblocks 100 not having any coating or laminate. The exposed surfaces 1010can correspond to surfaces to be used for welding, bonding or connectingto terminals of battery cells 105. The coated surfaces 1005 and theexposed surface 1010 can be formed in a regular pattern across a topsurface of the battery blocks 100. For example, the coated surfaces 1005and the exposed surfaces 1010 can alternate across the top surface ofthe battery blocks 100 in a pattern corresponding to the arrangement ofthe battery cells 105 of the respective battery blocks 100. Thus, thepattern for the coated surfaces 1005 and the exposed surfaces 1010 cancorrespond to the arrangement of the battery cells 105 of the respectivebattery blocks 100.

The term weld is sometimes used herein by way of illustration (e.g., inresistive/laser welding or electrically connecting a current collectorto a terminal), and is not intended to be limiting in any way to aspecific manner of connection. As disclosed herein, the term weld issometimes used interchangeably with connect or bond (e.g., wirebond605). For example, the wirebond 605 can include a first end that iswelded, connected, or bonded with a surface of a battery cell 105 and asecond end that is welded, connected, or bonded with a conductivepositive layer 110 of the cell holder 125. The negative tab 205 caninclude a first end that is welded, connected, or bonded with a surfaceof at least two battery cells 105 and a second end that is welded,connected, or bonded with a conductive negative layer 120 of the firstcell holder 125.

FIG. 7 depicts a cross-section view 700 of an electric vehicle 705installed with a battery pack 740. The battery pack 740 can include aplurality of battery modules 500. The plurality of battery modules 500can include a plurality of battery blocks 100. The battery blocks 100can include a plurality of cylindrical battery cells 105. Each of theplurality of cylindrical battery cells 105 can include a positiveterminal 620 coupled with a first current collector 110 and a negativeterminal 625 coupled with a second current collector 120. The electricvehicle 705 can include an autonomous, semi-autonomous, ornon-autonomous human operated vehicle. The electric vehicle 705 caninclude a hybrid vehicle that operates from on-board electric sourcesand from gasoline or other power sources. The electric vehicle 705 caninclude automobiles, cars, trucks, passenger vehicles, industrialvehicles, motorcycles, and other transport vehicles. The electricvehicle 705 can include a chassis 710 (sometimes referred to herein as aframe, internal frame, or support structure). The chassis 710 cansupport various components of the electric vehicle 705. The chassis 710can span a front portion 715 (sometimes referred to herein a hood orbonnet portion), a body portion 720, and a rear portion 725 (sometimesreferred to herein as a trunk portion) of the electric vehicle 705. Thefront portion 715 can include the portion of the electric vehicle 705from the front bumper to the front wheel well of the electric vehicle705. The body portion 720 can include the portion of the electricvehicle 705 from the front wheel well to the back wheel well of theelectric vehicle 705. The rear portion 725 can include the portion ofthe electric vehicle 705 from the back wheel well to the back bumper ofthe electric vehicle 705.

The battery pack 740 that includes a plurality of cylindrical batterycells 105 having a positive terminal 620 coupled with a first currentcollector 110 and a negative terminal 625 coupled with a second currentcollector 120 can be installed or placed within the electric vehicle705. For example, the battery pack 740 can couple with a drive trainunit of the electric vehicle 705. The drive train unit may includecomponents of the electric vehicle 705 that generate or provide power todrive the wheels or move the electric vehicle 705. The drive train unitcan be a component of an electric vehicle drive system. The electricvehicle drive system can transmit or provide power to differentcomponents of the electric vehicle 705. For example, the electricvehicle drive train system can transmit power from the battery pack 740to an axle or wheels of the electric vehicle 705. The battery pack 740can be installed on the chassis 710 of the electric vehicle 705 withinthe front portion 715, the body portion 720 (as depicted in FIG. 7), orthe rear portion 725. A first bus-bar 735 and a second bus-bar 730 canbe connected or otherwise be electrically coupled with other electricalcomponents of the electric vehicle 705 to provide electrical power fromthe battery pack 740 to the other electrical components of the electricvehicle 705.

A battery pack 740 as described herein can refer to a battery systemhaving multiple battery modules 500 (e.g., two or more). Multiplebattery modules 500 can be electrically coupled with each other to forma battery pack 740, using one or more electrical connectors such asbus-bars. For example, battery blocks 100 can be electrically coupled orconnected to one or more other battery blocks 100 to form a batterymodule 500 or battery pack 740 of a specified capacity and voltage. Thenumber of battery blocks 100 in a single battery module 500 can vary andcan be selected based at least in part on a desired capacity of therespective battery module 500. The number of battery modules 500 in asingle battery pack 740 can vary and can be selected based at least inpart on a desired capacity of the respective battery pack 740. Forexample, the number of battery modules 500 in a battery pack 740 canvary and can be selected based at least in part on an amount of energyto be provided to an electric vehicle. The battery pack 740 can coupleor connect with one or more bus-bars of a drive train system of anelectric vehicle to provide electrical power to other electricalcomponents of the electric vehicle (e.g., as depicted in FIG. 7).

The battery blocks 100 and the battery modules 500 can be combinablewith one or more other battery blocks 100 and battery modules 500 toform the battery pack 740 of a specified capacity and a specifiedvoltage that is greater than that across the terminals of the batteryblock 100 or battery module 500. For instance, a high-torque motor maybe suitably powered by a battery pack 740 formed with multiple batterycells 105 (e.g., 500 cells), blocks 100 or modules 500 connected inparallel to increase capacity and to increase current values (e.g., inAmperes or amps) that can be discharged. A battery block 100 can beformed with 20 to 50 battery cells 105 for instance, and can provide acorresponding number of times the capacity of a single battery cell 105.A battery pack 740 formed using at least some battery blocks 100 orbattery modules 500 connected in parallel can provide a voltage that isgreater than that across the terminals of each battery block 100 orbattery module 500. A battery pack 740 can include any number of batterycells 105 by including various configurations of battery blocks 100 andbattery modules 500.

The battery module 500 or battery pack 740 having one or more batteryblocks 100 can provide flexibility in the design of the battery module500 or the battery pack 740 with initially unknown space constraints andchanging performance targets. For example, standardizing and using smallbattery blocks 100 can decrease the number of parts (e.g., as comparedwith using individual cells) which can decrease costs for manufacturingand assembly. The battery modules 500 or battery packs 740 having one ormore battery blocks 100 as disclosed herein can provide a physicallysmaller, modular, stable, high capacity or high power device that is notavailable in today's market, and can be an ideal power source that canbe packaged into various applications.

The shape and dimensions of the battery pack 740 can be selected toaccommodate installation within an electric vehicle. For example, thebattery pack 740 can be shaped and sized to couple with one or morebus-bars 730, 735 of a drive train system (which includes at least partof an electrical system) of an electric vehicle 705. The battery pack740 can have a rectangular shape, square shape, or a circular shape,among other possible shapes or forms. The battery pack 740 (e.g., anenclosure or outer casing of the battery pack 740) can shaped to hold orposition the battery modules 500 within a drive train system of anelectric vehicle 705. For example, the battery pack 740 can be formedhaving a tray like shape and can include a raised edge or border region.Multiple battery modules 500 can be disposed within the battery pack 740can be held in position by the raised edge or border region of thebattery pack 740. The battery pack 740 may couple with or contact abottom surface or a top surface of the battery modules 500. The batterypack 740 can include a plurality of connectors to couple the batterymodules 500 together within the battery pack 740. The connections mayinclude, but not limited to, straps, wires, adhesive materials, orfasteners.

The battery blocks 100 can be coupled with each other to form a batterymodule 500 and multiple battery modules 500 can be coupled with eachother to form a battery pack 740. The number of battery blocks 100 in asingle battery module 500 can vary and be selected based at least inpart on a desired capacity or voltage of the respective battery module500. The number of battery modules 500 in a single battery pack 740 canvary and be selected based at least in part on a desired capacity of therespective battery pack 740. For instance, a high-torque motor may besuitably powered by a battery pack 740 having multiple battery modules500, the battery modules 500 having multiple battery blocks 100 and thebattery blocks 100 having multiple battery cells 105. Thus, a batterypack 740 can be formed with a total number of battery cells ranging from400 to 600 (e.g., 500 battery cells 105), with the battery blocks 100 orbattery modules 500 connected in parallel to increase capacity and toincrease current values (e.g., in Amperes or amps) that can bedischarged. A battery block 100 can be formed with any number of batterycells 105 and can provide a corresponding number of times the capacityof a single battery cell 105.

Referring to FIG. 8, among others, an example embodiment of a method 800of providing current collection is depicted. The method 800 can includeproviding a battery pack 740 (ACT 805). The battery pack 740 can bedisposed within an electric vehicle 705. The battery pack 740 can beformed having multiple battery modules 500. For example, two or morebattery modules 500 can be electrically coupled together to form abattery pack 740. The battery module 500 can be formed by electricallycoupling two or more battery blocks 100 together. For example, batteryblock terminals 610, 615 can electrically couple a first battery block100 with a second battery block 100 to form at least one battery module500. The battery blocks 100 can be electrically coupled in series. Thebattery blocks 100 can be electrically coupled in parallel.

The method 800 can include disposing a plurality of cylindrical batterycells 105 within at least one battery block 100 (ACT 810). The batterycells 105 can be disposed such that they are uniformly spaced, evenlyspaced within a common battery block 100 or the battery cells 105 can bedisposed such that they are spaced one or more different distances fromanother one or more battery cells 105 of the common battery block 100.Disposing the battery cells 105 can include spacing the battery cells105 from a neighboring or adjacent battery cell 105 in all directions bya distance that ranges from 0.5 mm to 3 mm (e.g., 1.5 mm spacing betweeneach battery cell 105, 2 mm spacing between each battery cell 105).Disposing the battery cells 105 can include spacing one or more batterycells 105 a common battery block 100 one or more battery cells 105 oneor more different distances from another one or more battery cells 105of the common battery block 100. Depending on the shape of each batterycell 105, the battery cells 105 can be arranged spatially relative toone another to reduce overall volume of the battery block 100, to allowfor minimum cell to cell spacing (e.g., without failure or degradationin performance), or to allow for an adequate number of vent ports. Forexample, disposing the battery cells 105 can include arranging each rowof battery cells in a slanted or offset formation relative to oneanother. The battery cells 105 can be placed in various other formationsor arrangements.

The method 800 can include aligning a plurality of apertures 140, 145,150 (ACT 815). For example, the first conductive layer 110, theisolation layer 115, and the second conductive layer 120 can be formedhaving a plurality of apertures 140, 145, 150, respectively. Thus,aligning the plurality of apertures 140, 145, 150 can include aligning afirst plurality of apertures 140 of a first current collector 110 havinga first conductive layer. The first plurality of apertures 140 can bealigned to expose positive terminals 620 of the plurality of cylindricalbattery cells 105 through the first conductive layer to connect to thefirst conductive layer. Aligning the plurality of apertures 140, 145,150 can include aligning a second plurality of apertures 145 of anisolation layer 115. The second plurality of apertures 145 can bealigned to expose the positive terminals 620 of the plurality ofcylindrical battery cells 105 through the isolation layer 115 to connectto the first conductive layer. The isolation layer 115 can be disposedto electrically isolate the first current collector 110 from the secondcurrent collector 120. Aligning the plurality of apertures 140, 145, 150can include aligning a third plurality of apertures 150 of a secondcurrent collector 120 having a second conductive layer. The thirdplurality of apertures 150 can be aligned to expose the positiveterminals of the plurality of cylindrical battery cells 105 through thesecond conductive layer to connect to the first conductive layer, and toexpose portions of the negative terminals 625 of the plurality ofcylindrical battery cells 105 to connect to the second conductive layer.

Aligning the plurality of apertures 140, 145, 150 can include exposingpositive terminals of a plurality of battery cells 105 through therespective layers. The isolation layer 115 can include a nonconductivelayer or non-conductive material, and can electrically isolate the firstcurrent collector 110 from the second current collector 120. Thepluralities of apertures 140, 145, 150 can be aligned by maximizingareas of all or a part of the pluralities of apertures 140, 145, 150that is unobstructed by any of the layers. The pluralities of apertures140, 145, 150 can be aligned by aligning the boundaries of the apertures140, 145, 150 between the layers. The pluralities of apertures 140, 145,150 can be aligned by using a jig, setting mold or tool to align betweenthe layers.

Portions of the first current collector 110, the isolation layer 115,and the second current collector 120 can be laminated. For example,portions of surfaces of the first current collector 110 can be coatedwith a laminate material. Other portions of the surfaces of the firstcurrent collector 110 can be left exposed or not coated with anylaminate material. For example, surfaces of the first current collector110 to be used for wirebonding can be left exposed to provide a contactpoint for the wirebonding. Surfaces not to be used for wirebonding canbe coated with a laminate material.

Portions of surfaces of the isolation layer 115 can be coated with alaminate material. For example, the isolation layer 115 can be laminatedto provide isolation between the first current collector 110 and thesecond current collector 120. The isolation layer 115 can be disposedbetween the first current collector 110 and the second current collector120 with laminated surfaces in contact with the first current collector110 and the second current collector 120. Portions of surfaces of thesecond current collector 120 can be coated with a laminate material.Other portions of the surfaces of the second current collector 120 canbe left exposed or not coated with any laminate material. For example,surfaces of the second current collector 120 to be used for wirebondingcan be left exposed to provide a contact point for the wirebonding.Surfaces not to be used for wirebonding can be coated with a laminatematerial.

The battery cells 105 can be aligned or arranged within the batteryblock 100 using a first cell holder 125 and a second cell holder 130.For example, the first cell holder 125 can hold, house or align theplurality of battery cells 105 using a fourth plurality of apertures155. The second cell holder 130 can hold, house or align the pluralityof battery cells 105 using a fifth plurality of apertures 160. The firstcell holder 125 can be coupled with or include the first currentcollector 110, the isolation layer 115, and the second current collector120. The battery cells 105 can be disposed such that a first end or topsurface is couple with the first cell holder 125 and a second end orbottom surface is coupled with the second cell holder 130. Thus, thefirst cell holder 125 and the second cell holder 130 can arrange thebattery cells in place.

The method 800 can include connecting the first current collector 110with the battery cells (ACT 820). The first current collector 110 cancorrespond to a first conductive layer or positive conductive layer andcan be electrically coupled with the positive terminals of the pluralityof battery cells 105. The first current collector 110 can be coupledwith or connected to the positive terminal of each of the plurality ofcylindrical battery cells 105 via welding (e.g., laser welding) or wirebonding. For example, a wirebond 605 can couple each battery cell 105with a surface or portion of the first current collector 110. Thewirebond 605 can be positioned such that it extends through one or moreof the apertures 140, 145, 150 to contact a positive terminal of abattery cell 105 and the surface or portion of the first currentcollector 110. For example, a wirebonding tool can attach or connect abondhead or end of a wirebond 605 to or near a center of a positiveterminal of the battery cell 105, and another bondhead or end of thewirebond 605 to an uncoated or uninsulated surface of the first currentcollector 110. A wirebonding tool can access the positive terminal ofthe battery cell 105 exposed by one or more of the apertures 140, 145,150, and can connect one end of a wirebond to the positive terminal. Thewirebonding tool can connect another end of the wirebond to a surface ofan uncoated or uninsulated surface of the first current collector 110.

The method 800 can include connecting the second current collector 120with the battery cells (ACT 825). The second current collector 120 cancorrespond to a second conductive layer or negative conductive layer,and can be electrically coupled with a rim 135 of each of the pluralityof battery cells 105. The rims 135 can correspond to negative terminalsof the plurality of battery cells 105. The rims 135 of at least twobattery cells 105 can be aligned or positioned within a battery block100 such that a negative tab 205 of the second current collector 120couples with or contacts with the rims 135 of at least two battery cells105.

The second current collector 120 can be connected to the rim 135 of eachof the plurality of battery cells 105 via welding (e.g., laser welding)or wire bonding. For example, the negative tab 205 of the second currentcollector 120 can be welded or wire bonded to rims 135 of a battery cell105 or two battery cells 105. Each of the positive terminals can belocated at a same end of a corresponding battery cell 105 as a connectedrim 135 of the corresponding battery cell 105. A wirebonding tool canaccess a rim 135 of a battery cell 105 exposed by one or more of theapertures 140, 145, 150, and can connect one end of a wirebond to therim 135. The wirebonding tool can access a negative tab 205 or otherportion of the second current collector 120, and can connect another endof the wirebond to a surface of the negative tab 205 or other portion ofthe second current collector 120. The isolation layer 115, comprising alamination layer, can hold or bind the first current collector 110 andthe second current collector 120 together. For example, the isolationlayer 115 may include a laminate material or adhesive material disposedover a first surface or a second surface of the isolation layer 115 suchthat the first current conductor 110 can be coupled with or adhered tothe first surface of the isolation layer 115 and the second currentcollector 120 can be coupled with or adhered to the second surface ofthe isolation layer 115.

Aperture edges of at least a portion of the plurality of apertures 140,145,150 of the first current collector 110 or the second currentcollector 120 can be electrically isolated from the positive terminalsof the plurality of battery cells 105. For example, method 800 caninclude coating the inner surface, edge, or inner rim of the apertures140, 145, 150 with a insulation layer or material to electricallyinsulate or electrically isolate a wirebond (e.g., positive wirebond)disposed in or extending through one or more of the apertures 140,145,150, from the first current collector 110 or the second currentcollector 120.

A first aperture 150 of the second current collector's 120 plurality ofapertures 150 can be created to have an area smaller than that of acorresponding aperture 140 of the first current collector 110 or acorresponding aperture 145 of the isolation layer 115. The firstaperture 150 of the second current collector 120 can be formed having anarea smaller than that of the corresponding aperture of the firstcurrent collector 110 or a corresponding aperture 145 of the isolationlayer 115 due to a negative tab 205 coupled with or formed with an edgeof the first aperture 150 of the second current collector 120. Forexample, the second current collector 120 can be formed having a tabbedportion, referred to herein as a negative tab 205, that extends orprotrudes towards a center of the respective aperture 150 of theplurality of apertures 150 of the second current collector 120. Each ofthe apertures the plurality of apertures 150 of the second currentcollector 120 may include at least one negative tab 205.

The negative tab 205 can extend or protrude such that it is the sameplane a surface of the second current collector 120 and thus a top orbottom surface of the negative tab 205 can be parallel with a top orbottom surface of the second current collector 120. The negative tab 205can be welded (e.g., laser welded) or bonded (e.g., wire bonded) to atleast one negative terminal of a cylindrical battery cell 105. A singlenegative tab 205 may be welded or bonded to two negative terminals oftwo different negative terminals of two different cylindrical batterycells 105. For example, portions (e.g., separate portions) of thenegative tab 205 can be welded or bonded to negative terminals of twocylindrical battery cell 105. Other portions or edges of the firstaperture can be welded or bonded to at least one negative terminal of acylindrical battery cell 105.

The positive terminals of the cylindrical battery cells 105 can beexposed through one or more of the apertures 140, 145, 150 formed in thefirst current collector 110, the isolation layer 115, and the secondcurrent collector 120, respectively. For example, two battery cells 105(e.g., a first battery cell 105 and a second batter cell 105) can beexposed through a first region 210 and a second region 215 of one ormore of the apertures 140, 145, 150 formed in the first currentcollector 110, the isolation layer 115, and the second current collector120, respectively.

A wirebond 605 can couple the positive terminals of the cylindricalbattery cells 105 with the first current collector 110. For example. Afirst wirebond 605 can couple the positive terminal of the first batterycell 105 with the first current collector 110 and a second wirebond 605can couple the positive terminal of the second battery cells 105 withthe first current collector 110. The first and second wirebonds 605 canextend through the apertures 140, 145, 150 to couple with a surface ofthe first current collector 110. The first and second wirebonds 605 canbe welded (e.g., laser welded) or bonded (e.g., wire bonded) to thepositive terminals of the first and second cylindrical battery cells105, respectively.

At least one edge of the first current collector 110 or the secondcurrent collector 120 can be formed to have at least onepartially-formed aperture to expose at least one positive terminal ofthe plurality of cylindrical battery cells 105 through a correspondinglayer. The partially formed apertures can be formed to allow a wirebond650 to couple with the positive terminals of the plurality ofcylindrical battery cells 105. The dimensions of the partially formedapertures can vary and can be selected based at least in part on thedimensions of the battery cells 105.

FIG. 9 depicts an example embodiment of a method 900 of providing asystem to power an electric vehicle 705. The method 900 can includeproviding a battery pack 740 (ACT 905). For example, the system to poweran electric vehicle 705 can include a battery pack 740. The battery pack740 can reside in the electric vehicle 705 and can include a pluralityof battery modules 500. Each of the plurality of battery modules 500 caninclude a plurality of battery blocks 100. A first battery block 100 ofthe plurality of battery blocks 100 can include a pair of battery blockterminals 610, 615. The first battery block 100 can include a pluralityof cylindrical battery cells 105. Each of the plurality of cylindricalbattery cells 105 can include a positive terminal 620 and a negativeterminal 625. A first current collector 110 can include a conductivelayer. The conductive layer of the first current collector 110 cancouple the first current collector 110 with positive terminals 620 ofthe plurality of cylindrical battery cells 105 at first ends of theplurality of cylindrical battery cells 105. A second current collector120 can include a conductive layer. The conductive layer of the secondcurrent collector 120 can be electrically isolated from the conductivelayer of the first current collector 110 by an isolation layer 115. Theconductive layer of the second current collector 120 can couple thesecond current collector 120 with negative terminals 625 of theplurality of cylindrical battery cells 105 at the first ends of theplurality of cylindrical battery cells 105. The first current collector110 can include a plurality of apertures 140 to expose the positiveterminals 620 of the plurality of cylindrical battery cells to couplewith the conductive layer of the first current collector 110. Theisolation layer 115 can include a plurality of apertures 145 to exposethe positive terminals 620 of the plurality of cylindrical battery cells105. The positive terminals 625 (or wirebonds 605) of the plurality ofcylindrical battery cells 105 can extend through the plurality ofapertures 145 of the isolation layer 115 to couple with the conductivelayer of the first current collector 110. The second current collector120 can have a plurality of apertures 150 to expose the positiveterminals 620 of the plurality of cylindrical battery cells 105 and toexpose portions of the negative terminals 625 of the plurality ofcylindrical battery cells 105 to connect to the conductive layer of thesecond current collector 120. The positive terminals 620 (or wirebonds605) of the plurality of cylindrical battery cells 105 can extendthrough the plurality of apertures 150 of the second current collector120 to couple with the conductive layer of the first current collector110.

While acts or operations may be depicted in the drawings or described ina particular order, such operations are not required to be performed inthe particular order shown or described, or in sequential order, and alldepicted or described operations are not required to be performed.Actions described herein can be performed in different orders.

Having now described some illustrative implementations, it is apparentthat the foregoing is illustrative and not limiting, having beenpresented by way of example. Features that are described herein in thecontext of separate implementations can also be implemented incombination in a single embodiment or implementation. Features that aredescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in varioussub-combinations. References to implementations or elements or acts ofthe systems and methods herein referred to in the singular may alsoembrace implementations including a plurality of these elements, and anyreferences in plural to any implementation or element or act herein mayalso embrace implementations including only a single element. Referencesin the singular or plural form are not intended to limit the presentlydisclosed systems or methods, their components, acts, or elements tosingle or plural configurations. References to any act or element beingbased on any act or element may include implementations where the act orelement is based at least in part on any act or element.

The phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including” “comprising” “having” “containing” “involving”“characterized by” “characterized in that” and variations thereofherein, is meant to encompass the items listed thereafter, equivalentsthereof, and additional items, as well as alternate implementationsconsisting of the items listed thereafter exclusively. In oneimplementation, the systems and methods described herein consist of one,each combination of more than one, or all of the described elements,acts, or components.

Any references to implementations or elements or acts of the systems andmethods herein referred to in the singular can include implementationsincluding a plurality of these elements, and any references in plural toany implementation or element or act herein can include implementationsincluding only a single element. References in the singular or pluralform are not intended to limit the presently disclosed systems ormethods, their components, acts, or elements to single or pluralconfigurations. References to any act or element being based on anyinformation, act or element may include implementations where the act orelement is based at least in part on any information, act, or element.

Any implementation disclosed herein may be combined with any otherimplementation or embodiment, and references to “an implementation,”“some implementations,” “one implementation” or the like are notnecessarily mutually exclusive and are intended to indicate that aparticular feature, structure, or characteristic described in connectionwith the implementation may be included in at least one implementationor embodiment. Such terms as used herein are not necessarily allreferring to the same implementation. Any implementation may be combinedwith any other implementation, inclusively or exclusively, in any mannerconsistent with the aspects and implementations disclosed herein.

References to “or” may be construed as inclusive so that any termsdescribed using “or” may indicate any of a single, more than one, andall of the described terms. References to at least one of a conjunctivelist of terms may be construed as an inclusive OR to indicate any of asingle, more than one, and all of the described terms. For example, areference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunctionwith “comprising” or other open terminology can include additionalitems.

Where technical features in the drawings, detailed description or anyclaim are followed by reference signs, the reference signs have beenincluded to increase the intelligibility of the drawings, detaileddescription, and claims. Accordingly, neither the reference signs northeir absence have any limiting effect on the scope of any claimelements.

Modifications of described elements and acts such as variations insizes, dimensions, structures, shapes and proportions of the variouselements, values of parameters, mounting arrangements, use of materials,colors, orientations can occur without materially departing from theteachings and advantages of the subject matter disclosed herein. Forexample, elements shown as integrally formed can be constructed ofmultiple parts or elements, the position of elements can be reversed orotherwise varied, and the nature or number of discrete elements orpositions can be altered or varied. Other substitutions, modifications,changes and omissions can also be made in the design, operatingconditions and arrangement of the disclosed elements and operationswithout departing from the scope of the present disclosure.

The systems and methods described herein may be embodied in otherspecific forms without departing from the characteristics thereof. Forexample the voltage across terminals of battery cells can be greaterthan 5V. The foregoing implementations are illustrative rather thanlimiting of the described systems and methods. Scope of the systems andmethods described herein is thus indicated by the appended claims,rather than the foregoing description, and changes that come within themeaning and range of equivalency of the claims are embraced therein.

Systems and methods described herein may be embodied in other specificforms without departing from the characteristics thereof. For example,descriptions of positive and negative electrical characteristics may bereversed. For example, elements described as negative elements caninstead be configured as positive elements and elements described aspositive elements can instead by configured as negative elements.Further relative parallel, perpendicular, vertical or other positioningor orientation descriptions include variations within +/−10% or +/−10degrees of pure vertical, parallel or perpendicular positioning.References to “approximately,” “about” “substantially” or other terms ofdegree include variations of +/−10% from the given measurement, unit, orrange unless explicitly indicated otherwise. Coupled elements can beelectrically, mechanically, or physically coupled with one anotherdirectly or with intervening elements. Scope of the systems and methodsdescribed herein is thus indicated by the appended claims, rather thanthe foregoing description, and changes that come within the meaning andrange of equivalency of the claims are embraced therein.

What is claimed is:
 1. A system to power electric vehicles, comprising:a battery pack to power an electric vehicle, the battery pack residingin the electric vehicle and comprising a plurality of battery modules;each of the plurality of battery modules comprising a plurality ofbattery blocks; a first battery block of the plurality of battery blockshaving a pair of battery block terminals, the first battery blockcomprising a plurality of cylindrical battery cells; each of theplurality of cylindrical battery cells having a positive terminal and anegative terminal; a first current collector having a conductive layer,the conductive layer of the first current collector coupling the firstcurrent collector with the positive terminals of the plurality ofcylindrical battery cells at first ends of the plurality of cylindricalbattery cells; a second current collector having a conductive layer, theconductive layer of the second current collector electrically isolatedfrom the conductive layer of the first current collector by an isolationlayer, the conductive layer of the second current collector coupling thesecond current collector with the negative terminals of the plurality ofcylindrical battery cells at the first ends of the plurality ofcylindrical battery cells; the first current collector having aplurality of apertures to expose the positive terminals of the pluralityof cylindrical battery cells to couple with the conductive layer of thefirst current collector; the isolation layer having a plurality ofapertures to expose the positive terminals of the plurality ofcylindrical battery cells, the positive terminals of the plurality ofcylindrical battery cells extend through the plurality of apertures ofthe isolation layer to couple with the conductive layer of the firstcurrent collector; the second current collector having a plurality ofapertures to expose the positive terminals of the plurality ofcylindrical battery cells and to expose portions of the negativeterminals of the plurality of cylindrical battery cells to connect tothe conductive layer of the second current collector; and the positiveterminals of the plurality of cylindrical battery cells extend throughthe plurality of apertures of the second current collector to couplewith the conductive layer of the first current collector.
 2. The systemof claim 1, comprising: a plurality of wirebonds that respectivelycouple the first current collector with the positive terminals of theplurality of cylindrical battery cells.
 3. The system of claim 1,comprising: the first current collector welded with the positiveterminals of the plurality of cylindrical battery cells.
 4. The systemof claim 1, comprising: the isolation layer including a lamination layerto hold the first current collector and the second current collectortogether.
 5. The system of claim 1, comprising: at least a portion ofthe plurality of apertures of the second current collector havingaperture edges that are electrically isolated from the positiveterminals of the plurality of cylindrical battery cells.
 6. The systemof claim 1, comprising: each aperture of the plurality of apertures ofthe second current collector having an area smaller than an area of eachaperture of the plurality of apertures of the first current collector.7. The system of claim 1, comprising: each aperture of the thirdplurality of apertures of the second current collector having an areasmaller than an area of each aperture of the first plurality ofapertures of the first current collector due to a protruding edgeprotruding towards a center of each aperture of the third plurality ofapertures of the second current collector.
 8. The system of claim 7,wherein the protruding edge is welded to at least one of the negativeterminals.
 9. The system of claim 7, wherein the protruding edge isbonded to at least one of the negative terminals.
 10. The system ofclaim 1, comprising: the plurality of apertures of the first currentcollector and the plurality of apertures of the second current collectorto spatially align the plurality of cylindrical battery cells relativeto each other to at least meet creepage-clearance requirements of thebattery block to provide a voltage of at least 400 volts across apositive terminal and a negative terminal of the battery block.
 11. Thesystem of claim 1, comprising: at least one edge of the first currentcollector having at least one partially-formed aperture configured toexpose at least one positive terminal of the plurality of cylindricalbattery cells to connect to the conductive layer of the first currentcollector.
 12. The system of claim 1, comprising: at least one edge ofthe second current collector having at least one partially-formedaperture configured to expose at least one positive terminal of theplurality of cylindrical battery cells through the second conductivelayer to connect to the conductive layer of the first current collector.13. The system of claim 1, comprising: the battery pack disposed in theelectric vehicle.
 14. The system of claim 1, comprising: the batterypack disposed in the electric vehicle; the first current collectorcoupled with a first busbar of the electric vehicle to provide electricpower from the battery pack to the electric vehicle; and the secondcurrent collector coupled with a second busbar of the electric vehicleto provide electric power from the battery pack to the electric vehicle.15. A method of providing a system to power an electric vehicle, themethod, comprising: providing a battery pack to power an electricvehicle, the battery pack residing in the electric vehicle andcomprising a plurality of battery modules, each of the plurality ofbattery modules comprising a plurality of battery blocks, a firstbattery block of the plurality of battery blocks having a pair ofbattery block terminals; disposing a plurality of cylindrical batterycells in the first battery block, each of the cylindrical battery cellshaving a positive terminal and a negative terminal; aligning a pluralityof apertures of a first current collector having a conductive layer, theplurality of apertures of the first current collector aligned to exposethe positive terminals of the plurality of cylindrical battery cells tocouple with the conductive layer of the first current collector;aligning a plurality of apertures of an isolation layer, the pluralityof apertures of the isolation layer aligned to expose the positiveterminals of the plurality of cylindrical battery cells, the positiveterminals of the plurality of cylindrical battery cells extendingthrough the plurality of apertures of the isolation layer to couple withthe conductive layer of the first current collector; aligning aplurality of apertures of a second current collector having a conductivelayer, the plurality of apertures of the second current collectoraligned to expose the positive terminals of the plurality of cylindricalbattery cells to couple with the conductive layer of the first currentcollector, the plurality of apertures of the second current collectoraligned to expose portions of the negative terminals of the plurality ofcylindrical battery cells to connect to the conductive layer of thesecond current collector; connecting the first current collector to thepositive terminals of the plurality of cylindrical battery cells atfirst ends of the plurality of cylindrical battery cells; and connectingthe second current collector to the negative terminals of the pluralityof cylindrical battery cells at the first ends of the plurality ofcylindrical battery cells.
 16. The method of claim 15, comprising:connecting the first current collector to the positive terminals of theplurality of cylindrical battery cells via wire bonding.
 17. The methodof claim 15, comprising: forming each aperture of the plurality ofapertures of the second current collector to have an area smaller thanan area of each aperture of the plurality of apertures of the firstcurrent collector due to a protruding edge protruding towards a centerof each aperture of the plurality of apertures of the second currentcollector.
 18. The method of claim 15, comprising: exposing positiveterminals of two of the plurality of cylindrical battery cells throughat least one of the plurality of apertures of the first currentcollector, through at least one of the plurality of apertures of thesecond current collector, and through at least one of the plurality ofapertures of the isolation layer.
 19. The method of claim 15,comprising: providing the battery block that includes the first currentcollector, the second current collector and the plurality of cylindricalbattery cells; and spatially aligning the cylindrical battery cellsrelative to each other, using the plurality of apertures of the firstcurrent collector and the plurality of apertures of the second currentcollector, to at least meet creepage-clearance requirements of thebattery block to provide a voltage of at least 400 volts across apositive terminal and a negative terminal of the battery block.
 20. Anelectric vehicle, comprising: a battery pack to power an electricvehicle, the battery pack residing in the electric vehicle andcomprising a plurality of battery modules; each of the plurality ofbattery modules comprising a plurality of battery blocks; a firstbattery block of the plurality of battery blocks having a pair ofbattery block terminals, the first battery block comprising a pluralityof cylindrical battery cells; each of the plurality of cylindricalbattery cells having a positive terminal and a negative terminal; afirst current collector having a conductive layer, the conductive layerof the first current collector coupling the first current collector withthe positive terminals of the plurality of cylindrical battery cells atfirst ends of the plurality of cylindrical battery cells; a secondcurrent collector having a conductive layer, the conductive layer of thesecond current collector electrically isolated from the conductive layerof the first current collector by an isolation layer, the conductivelayer of the second current collector coupling the second currentcollector with the negative terminals of the plurality of cylindricalbattery cells at the first ends of the plurality of cylindrical batterycells; the first current collector having a plurality of apertures toexpose the positive terminals of the plurality of cylindrical batterycells to couple with the conductive layer of the first currentcollector; the isolation layer having a plurality of apertures to exposethe positive terminals of the plurality of cylindrical battery cells,the positive terminals of the plurality of cylindrical battery cellsextend through the plurality of apertures of the isolation layer tocouple with the conductive layer of the first current collector; thesecond current collector having a plurality of apertures to expose thepositive terminals of the plurality of cylindrical battery cells and toexpose portions of the negative terminals of the plurality ofcylindrical battery cells to connect to the second conductive layer; andthe positive terminals of the plurality of cylindrical battery cellsextend through the plurality of apertures of the second currentcollector to couple with the conductive layer of the first currentcollector.